Flow Meter Applications and Flow Measurement
SmartMeasurement™ is among the world‘s leading process measurement companies involved in the development and production of industrial flow meter technologies. Flow measurement technologies provided by SmartMeasurement™ include differential pressure flow meters, magnetic flow meters, ultrasonic flow meters, positive displacement flowmeters, turbine flowmeters, variable area flowmeters, vortex flowmeters, Coriolis mass flow meters, and thermal flow meters.
We provide our customers with the best fit application solutions by combing our over 25 years of experience in developing and managing global sales networks with our engineering and manufacturing capabilities. Our products consistently meet or exceed our users’ expectations in terms of quality, performance capability, service, and design.
Our industrial solutions section provides hundreds—if not thousands—of well-known and successful applications in many industries. Regardless of your industry, SmartMeasurement™ offers you not only flow and pressure measuring devices for virtually any medium, but also the expertise to provide our customers with the best solutions in terms of both economic and technical merits for any given applications. Our focus is not only on well-known industrial applications, but also unique and custom products to meet our customer’s needs.
Click on your industry to see the many application solutions we have in store for you. Request a quote on industrial flow meters for your application, or if you do not see your application, please contact us about your specific needs. We look forward to working with you to develop an ideal solution.
Flow Meters in Building Automation
SmartMeasurement™’s products have been used successfully in many Building Automation flow measurement and energy measurement projects. Our AlsonicEG and AlmagEG energy flow meters have been used in water and energy measurement for chiller optimization, hot water consumption monitoring, and primary & secondary heat exchanger flow monitoring. SmartMeasurement™’s ultrasonic flow meters have been used for energy balancing optimization while our electromagnetic flowmeters have been used for chemical addition optimization and other water & energy controls applications. The ATMF series thermal flowmeters have been used for air handling and fan coil control and hot air measurement. Our ALVT vortex flow meters are commonly used for evaporation losses and other building steam measurement applications. SmartMeasurement™ provides a one-stop shop for all of your energy meter and flow metering requirements in the Building Automation industry.
HVAC (Heat Ventilation & Air Conditioning)
A comprehensive metering program is essential to effectively manage and conserve HVAC resources in buildings. While traditional methods using a building control system is to calculate energy building optimization, SmartMeasurement™’s wide range of energy flow meters offer superior accuracies with N.I.S.T. traceable calibration for the entire measurement system in HVAC industries. With an integral display and multiple outputs, SmartMeasurement™ wide range of energy flow meters provide, flow, temperature, energy consumption, etc. The SmartMeasurement™ AlsonicEG ultrasonic energy meters have been used to effectively measure and control hot & cold water to optimize building cooling systems. Operation costs as high as 30% have been saved in effectively controlling the usage of hot and cold water. The uses of SmartMeasurement™ wide range of energy flow meters can lead to system capacity analysis; individual building cost allocation and energy efficiency; hydronic system optimization (kw/ton) and troubleshooting, etc.
• SmartMeasurement™ wide range of energy flow meters provide, flow, temperature, energy consumption, etc.
• The SmartMeasurement™ AlsonicEG ultrasonic energy meters have been used to effectively measure and control hot & cold water to optimize building cooling systems.
• SmartMeasurement™ s wide range of energy flow meters offer superior accuracies with N.I.S.T. traceable calibration.
Hot and Chilled water
Universities, Hospitals, Shopping Malls and all commercial buildings have central energy plants that provide chilled and hot water distribution throughout the buildings. The energy plants are often times managed by facility management companies that bill their customers for the amount hot water or chilled water being used. Often times Internal utility bills were based on square footage of conditioned space and this fixed cost method offered no incentive for energy conservation by individual building managers. SmartMeasurement™ offers a wide variety of Energy flow meters. Our AlsonicEG ultrasonic energy meters is used as a non-intrusive energy flow meter without interrupting the flow of heating and cooling water to the buildings. This saves a consider amount of installation and operation costs since there is no need for flow shut down or cutting the pipe to install. However should water pipes have some particulates or bubbles while needing higher accuracies than ultrasonic energy meters, the SmartMeasurement™ energy flow meter also comes in electromagnetic technology, the AlmagEG will be the instrument of choice.
The installation of the SmartMeasurement™ energy flow meter systems provides critical information needed for the planning of future buildings while providing accurate billing for the entire building or each floor. A systems that uses multi-technology SmartMeasurement™ energy flow meters it promotes energy conservation by identifying problem areas and large energy users and bill them accordingly. “This is a win-win situation for everyone. Building maintenance managers who have control over their budget and energy costs can recover the cost that is incurred by the use of less energy which is also better for the environment.
• SmartMeasurement™ offers a wide variety of Energy flow meters coming in both ultrasonic and magnetic technologies which offers application flexibility to plant managers.
• When water pipes have some particulates or bubbles while needing higher accuracies than ultrasonic energy meters, the SmartMeasurement™ energy flow meter also comes in electromagnetic technology, the AlmagEG will be the instrument of choice.
In combined heating and cooling applications the SmartMeasurement™ AlsonicEG ultrasonic energy flow meter is the best choice. The AlsonicEG provides high accurate energy measurements for applications such as special treated water with low electric conductivity and magnetite and buildings where the air-conditioning can’t be turned off. The AlsonicEG enables retrofitting of transducers under pressure with clamp-on non-intrusive installation methods for a cost effective solution.
The AlsonicEG ultrasonic thermal energy flow meter is a non-intrusive instrument, which is used to accurately measure flow, temperature and thermal energy consumption (BTU). The transducer can be clamped onto to any pipe from ½ -40” (15-1000mm), without cutting the pipe or shutting down the flow at various temperature range. The AlsonicEG does not have any moving parts to wear and tear, thus, saving maintenance costs.
The AlsonicEG energy flow meter utilizes transit-time technology and a patented digital signal processing algorithm for better accuracy and turn-downs and with its low flow capabilities as leakage detection in a complicated pipeline networks. A number of AlsonicEG units can be installed on the chiller distribution pipelines with their signals going to the control room for optimization. The AlsonicEG sends a vast amount of data in Mbus, Bacnet, MODBUS and other protocols to the BMS system for usage analysis.
Moreover the AlsonicEG.
• SmartMeasurement™ AlsonicEG ultrasonic energy flow meter is a non-intrusive instrument, which is used to accurately measure flow, temperature and thermal energy consumption (BTU).
• The AlsonicEG sends a vast amount of data in Mbus, Bacnet, MODBUS and other protocols to the BMS system for usage analysis
ENERGY FLOW METERS WITH MORE THAN 1-2% BUBBLES or PARTICLES IN PIPE
Electromagnetic Energy Flow Meters are used when there are more than 1-2% bubbles or particles in the pipe or wherever higher accuracies of greater than 1% are required. The AlmagEG series Electromagnetic Flow Meter complete with integral or remote flow transmitter offers higher accuracies than the ultrasonic energy flow meters.
The flow transmitter includes a backlit graphic display and keypad. Connections to the piping are usually ANSI class flanges (DIN or JIS is also available). The flow tubes are epoxy coated steel; the sensing electrodes are 316SS; the liner can be polypropylene or ebonite for low temperature service, PTFE for hot water service. Each flow meter is individually wet-calibrated and accurate to within ±0.2% of reading from 0.3 – 32 feet/sec (0.1 – 10 m/s) velocity. A N.I.S.T. certificate of calibration will be provided with each energy flow meter.
The AlmagEG energy flow meter calculates energy consumptions, energy loss as well as many other important functions suited for thermal energy applications. The AlmagEG energy flow meter is also well suited for cooling applications with low differential temperature as well as general cooling and heating systems. Outputs can be 4-20mA and programmable pulse as well as various digital signals such as MODBUS, BACNET, and MBUS etc. The AlmagEG energy flow meter is also capable of measuring bi-directional flow. Each AlmagEG energy flow meter is factory programmed for its specific application, and can be re-programmable using its keypad.
• The SmartMeasurement™ AlmagEG Electromagnetic Energy Flow Meters are used when there are more than 1-2% bubbles or particles in the pipe or wherever higher accuracies of greater than 1% are required
• The AlmagEG energy flow meter is also well suited for cooling applications with low differential temperature as well as general cooling and heating systems.
Steam flow measurement for District Heating
District heating, distributes heat generated from a centralized location to residential or commercial for heating requirements such ass pace heating and water heating. The heat is often obtained from a cogeneration plant that burns either fossil fuels or biomass. District heating plants can provide higher efficiencies and better pollution control than localized boilers. Facility managers often times estimate steam flow by measuring condensate or using vortex meters to measure the total output of steam generated and distributed to each building. Since steam flow is greatly affected by changes in pressure and/or temperature, an integral steam mass flow solution such as the SmartMeasurement™ ALVT-Mass. The ALVT-Mass with its capability of measuring five flow parameters with one process connection, calculates true mass flow directly by using its integral temperature and pressure sensors. By capturing virtually all district energy market worldwide, mass flow vortex meters such as the ALVT-Mass has become the “steam meter” for industry. Other features include insertion style for large pipes, high turndown, field-configurable with onboard diagnostic electrons and no moving parts to prevent wear and tear.
• The SmartMeasurement™ ALVT-Mass with its capability of measuring five flow parameters with one process connection, calculates true mass flow directly by using its integral temperature and pressure sensors
• The SmartMeasurement™ ALVT-Mass has become the “steam meter” for industry because not only it measure mass flow directly, it also comes in insertion style for large pipes, high turndown, field-configurable with onboard diagnostic electrons and no moving parts to prevent wear and tear.
Measuring low flow steam with existing piping
Building engineers always over engineer their systems with oversized piping. The oversized piping in steam flow meter applications makes it very difficult to measure low flows should process engineers deem it is necessary for their analysis. Often times a smaller flowmeter capable in measuring lower flows are needed but existing piping may be too difficult to change. However, the SmartMeasurement™ ALVT inline vortex flow meters are designed to fit in any existing pipe but measure lower flows than other vortex flow meter. The flanged type ALVT vortex flow meters can have a much smaller flow section down to ½ of the inlet section, enabling it to measure very low flows. Moreover when there is a reduction in steam requirements, customers can save thousands of dollars in installation costs by not having to down size the piping. The ALVT-Mass integral vortex mass meters can measure the wide range of demand between the summers and winter months where temperatures or pressure changes thereby effective steam usage.
• The SmartMeasurement™ ALVT inline vortex flow meters are designed to fit in any existing pipe but measure lower flows than other vortex flow meter to for building steam metering.
• The ALVT-Mass integral vortex mass meters can measure the wide range of demand between the summers and winter months where temperatures or pressure changes thereby effective steam usage.
SmartMeasurement™’s flowmeters have been successfully used in a variety of applications in the Chemical Industry. Examples include using ultrasonic flowmeters or all-ceramic electromagnetic flowmeters to measure acids and other corrosive materials, using mass flow meters to mass balancing of gases and liquids, and mass flow meters in mixing and batching applications where the recipe is written based on mass units of measure instead of volumetric. SmartMeasurement™ provide a one-stop shop for all flow metering requirement in the Chemical and Petro-chemical industries.
Sulfuric acids measurement
Titanium dioxide is a chemical compound used in making paints, cosmetics, plastics, and other products and is processed either by chlorine or sulfates. Usually the diluted acid is completely reprocessed in separated recycling plants and then fed back into the production process. Such a recycling takes place by concentrating the diluted acid to a certain threshold and then feeding it into several vacuum evaporators, arranged one after another, to subsequently reach concentration levels above 60%.
During inspection and maintenance, the recycling plants are shut down. When the plant comes back online, the pumps, which convey the diluted acid flow to the evaporators, are particularly subject to enormous stresses from the rapid rise temperature. A non-intrusive ultrasonic flowmeter such as our AlsonicDSP, with its ability to measure liquid flows containing up to 30% particulates or bubbles, provides an excellent solution for measuring the acid flow to the evaporators while minimizing the amount of wear of the pumps. The clamp-on transducers employed by the AlsonicDSP lend themselves to applications with larger pipe sizes because the line does not need to be broken in order to install them and because they are much more inexpensive than large, in-line style meters. Since the clamp-on ultrasonic transducers are simply mounted on the outside of the plastic pipes, they are not subject to any mechanical wear-and-tear by the aggressive medium or the solid particles contained therein.
By retrofitting with the AlsonicDSP ultrasonic flow meter, which may be installed during ongoing operation, the plant restart could be optimized effectively, not only in regard to lower wear of the pumps but also in regard to a reduction in the degree of solid particles caking in the heat exchangers, which in turn effects the overall energy efficiency of the plant.
• Reliable, non-intrusive flow measurement – no need to cut the pipe for installation
• No corrosion or wear and tear caused by solid particles carried in the liquid flow
• No risk of leakages
• Cost-effective retrofitting without any impact on the pipe system or interruption of the process operation
• Robust fixed ultrasonic flow meter systems such as the AlsonicDSP ultrasonic flow meter may be used in harsh industrial environments
Hydrofluoric Acid measurement
Hydrofluoric Acid is an aggressive acid used in producing Teflon®. Liquid flow meters used with this highly corrosive fluid must be lined with specialty plastics like PTFE. Electromagnetic flow meters with PTFE liners and corrosion resistant materials such as SmartMeasurement™’s AlamgWP offer one option for these applications. If plant operators cannot shut down their process, the SmartMeasurement™ AlsonicDSP family of clamp-on ultrasonic flow meters, provide another viable alternative. The ultrasonic flow meters come with transducers which are installed outside the pipe wall and never come into contact with the harsh acids. An added benefit is that shutting down the process is not necessary for installation or maintenance.
The AlsonicDSP, not only measures the volumetric flow rate, but also the sonic velocity of the liquid. A PLC or DSC can be programed to correlate acid concentration level to the measures sonic fluid velocity as there is a direct relationship between sonic velocity and changes of Hydrofluoric Acid concentration. This allows the operator to also supervise the concentration of the Hydrofluoric Acid running through the pipe (range between 45 – 65% conc).
• Non-intrusive AlsonicDSP ultrasonic flow meter – no media contact, no leakage risk
• Long service life with virtually no maintenance required
• Additional concentration measurement by programing a controller to determine the changes in concentration of acids versus sonic velocity.
• AlamgWP with Teflon liners or AlmagWC with all ceramic construction offers better accuracy of up to 0.2% vs. 0.5% for ultrasonic meters; however process shutdown is required for installation.
Sodium Hydroxide measurement
Sodium Hydroxide (NaOH) is produced by means of electrolysis and then distributed via piping to the respective production plants for further processing. A stable concentration of the Sodium Hydroxide is thus obligatory and has to be monitored very closely. Inline instrumentation, such as previously installed density meters, and inline liquid flow meters regularly failed due to the harsh conditions.
The AlsonicDSP ultrasonic flow meter , not only measures the volumetric flow rate, but also the sonic velocity of the liquid, a PLC or DSC can be programed to related acid concentration level versus fluid sonic velocity. There is a direct relationship between sonic velocity and changes of Sodium Hydroxide concentration. The operator is now able to also supervise the concentration of the Sodium Hydroxide running through the pipe. If the measured values deviate from the preset values, the process is automatically regulated.
• Reliable, non-intrusive flow and concentration measurement
• Installation without process interruption
• No media contact, no wear on the instrumentation, no risk of leaks
• Drift-free measurement and long term stable life
• AlamgWP with Teflon liners or AlmagWC with all ceramic construction offers better accuracy of up to 0.2% vs. 0.5% for ultrasonic meters; however process shutdown is required for installation
Ammonia and Nitric Acids measurement
In production sites for Ammonia (NH3) and Nitric Acid (HNO3), often times operators rely on a radiometric analyzer for the concentration measurement of a watery Ammonia solution. Besides the difficulties in handling the radioactive materials of the analyzer, the measurement readings are unstable and may differ from the laboratory samples. Inaccurate readings of the online measurement can lead to an over concentration of the Ammonia solution (between 0.5 to 1.0%) and thus increased costs for the operator. Therefore, an accurate non-intrusive flow transmitter with its ability to infer concentration level is a superior solution.
The AlsonicDSP ultrasonic flow meter , not only measures the volumetric flow rate, but also the sonic velocity of the liquid, a PLC or DSC can be programed to relate acid concentration levels versus fluid sonic velocity. There is a direct relationship between sonic velocity and changes of concentration. The operator is now able to also supervise the concentration of the fluids running through the pipe. If the measuring values deviate from the preset values, the process is automatically regulated.
With the AlsonicDSP ultrasonic flow meter , the plant operator is now able to reliably measure the right concentration of the ammonia solution with an accuracy of 0.1 to 0.3% – always matching the laboratory results.
• Non-intrusive online concentration measurement – substitution of the inaccurate radioactive analyzer
• Reliable and accurate measurements with results that match the laboratory samples
• Clean and safe solution – no risk of leakages
Many chemical processes require large varying volumes of nitrogen, argon and oxygen for inert ion or purging, hydrogen as a catalyst, and many other gases. SmartMeasurement™’s ATMF series of thermal mass flow meters, measures mass flow directly without the need of external pressure and temperature compensation. SmartMeasurement™’s ATMF thermal mass flow meters measure very low gas flows for leakage monitoring with very little pressure drop in the process. The ATMF Series features wide flow turndown ratios up to 800:1, integral or remote electronic configurations, HART, or Modbus outputs and have both CSA/FM and ATEX approvals. Moreover NIST traceable calibration certificates are supplied with every flow meter.
• Direct mass flow measurement of any gas with actual gas calibration
• Excellent turn-down ratios, low flows of 0.02mps up to 203 mps
• The only thermal mass flow meter in the market that provides an in-situ calibration verification
Flare/waste gas monitoring
SmartMeasurement™’s ATMF series thermal mass flow meters are used to measure total gas flow to flare stacks and in feed lines to the main flare headers. The ATMF series thermal mass flow meters features a no-moving-parts design, high reliability with durable construction and extremely low flow range detection as mandated by EPA regulations. ATMF series thermal mass flow meters are also used to balance and optimize the control of blower/louver adjustment for smokeless flares. An optional retractable packing gland assembly permits hot tap installation and retraction of the flow element without system shutdown. User-friendly microprocessor-based electronics and a built-in keypad provides high performance, and easy on-site programming.
• Direct mass flow measurement of any gas with self-diagnostic capabilities
• Excellent for mass balancing and optimization control
• Complies with EPA and ISO standards for Greenhouse gas monitoring
Nitrogen gas supply
Nitrogen is used to control the process media or avoid unwanted contact of the process media with oxygen/air. Reactors are filled and /or blanketed during operation with nitrogen. Continuous flow monitoring of nitrogen feed lines can prevent excessive gas consumption, hazardous situations due to insufficient gas supply, and expensive gas leakages. The SmartMeasurement™ ALTS series thermal flow switches and ATMF series thermal mass flow meters are used for these applications and feature a wide flow range (turndown ratio), direct mass flow measurement, and no pressure drop in the process media.
• ATMF series thermal mass flow meters are an excellent choice for nitrogen purge lines
• ALTS series thermal flow switches detect flow/no flow conditions or set points above/below a certain flow rate; they can be an economical alternative to flow meters in monitoring leakage
• Both the ATMF and ALTS have excellent turn-down rations, low flows of 0.02 mps up to 203 mps
Natural gas supply lines
Monitoring natural gas flow to various areas of production is critical in keeping costs under control. In a chemical plant, various areas throughout the production plant require natural gas in the manufacture of the end product. The transportation of natural gas over great distances is a complex task, requiring specialized equipment and facilities to deliver the gas safely, efficiently and in a ready to-use form. Considerations include maintaining sufficient pipeline pressure, maintaining pipeline integrity and keeping moisture levels low.
Often time’s customers use vortex meters and flow computers to calculate mass flow was via pressure and temperature compensation fed into a flow computer. A better solution is to use one instrument such as the SmartMeasurement™ ATMF series thermal mass flow meter. There is no need for external pressure and temperature sensors or a flow computer to calculate mass flow. The ATMF Series offers better turndown ratios than other gas mass flowmeters, is available with integral or remote electronics, HART, or Modbus outputs and CSA/FM and ATEX approvals for highly explosive environments. A NIST traceable calibration certificate is supplied with every flow meter to validate its accuracy and performance.
• ATMF series thermal mass flow meters offer a better alternative than other gas flowmeters which require additional instruments such as pressure sensors, temperature sensors and flow computer by measuring mass flow with only one instrument.
Mass flow measurement for material in and out flows
Chemical plants built over ten years ago or more use weight measurement to measure the mass flow which wastes labor material costs by requiring samples to be taken to their laboratories. This type of old-fashioned and low-tech automation are influenced by many human factors which can result in low or unstable mass balancing of chemical fluids.
Chemical process engineers are now using the SmartMeasurement™ ALCM series of Coriolis mass flow meters for direct process mass flow measurement. Depending on its unique application features, SmartMeasurement™ offers a variety of unique Coriolis designs such as ALCMUT for higher flows, ALCMDT for lower flows or ALCM-MB with its micro-bend structure allowing for lower pressure drops.
The SmartMeasurement™ ALCM series of Coriolis mass flow meters offers a more accurate real-time measurement of materials, guarantees stability, and continuity of the mass flow measurement. With several flow tube designs, plant operators can chose which features best fit their applications. The production line with the SmartMeasurement™ series of Coriolis mass flow meters is highly stable, the qualification rate of the product is high, material metering is accurate, labor costs are reduced, laborers are liberated from many operations, and a great amount of cost is saved.
• Various ALCM Coriolis flow tube designs allows operators to choose which features best fit their applications
• Direct mass flow and density measurement of any liquid
• Excellent for mass balancing and optimization control
• Reduced labor costs by measuring mass flow of fluids in process without weighing fluids in the laboratory
Food and Beverage Applications
SmartMeasurement™’s flowmeters have been successfully used in the food and beverage industry in a variety of different applications. Our ALMAGWP electromagnetic flowmeter has been used to measure brewery fluids, juices, and d