Clamp-on ultrasonic flow measurement offers a non-intrusive method for accurately determining fluid flow within a pipe. By placing transducers on the outside of the pipe, ultrasonic signals are transmitted through the pipe wall and fluid. The difference in signal transit times provides a precise calculation of flow velocity. This technique eliminates the need for pipeline modifications, making it ideal for applications where operational continuity and low maintenance are critical.
Industrial Water Use – a Critical Resource
At one of the major industrial sites along the Lower Rhine, water is an indispensable raw material. It supports a wide range of applications – from chemical processing and energy generation to cooling and cleaning. The operator centrally supplies different grades of water, including drinking, demineralised, and large volumes of process and circulation water.
Annually, the site moves approximately 760 million cubic meters of water through a vast pipe network. The majority serves as process water for through-flow cooling and circulation water for temperature regulation. This scale of usage is energy-intensive, with hundreds of pumps and drives consuming around 240,000 megawatt hours of electricity each year.
Optimising water use isn’t just an environmental goal – it’s an economic and energy imperative. And optimisation starts with accurate measurement.
The Measurement Challenge
Historically, a measuring orifice was used to monitor raw water flow into a storage tank, providing a reliable means of capturing key data. As operational demands evolved, and the focus shifted toward energy efficiency and streamlined maintenance, engineers began exploring alternative technologies. The goal was to implement a modern solution that could be integrated seamlessly – without requiring service interruptions or modifications to existing infrastructure.
Clamp-On Ultrasonic Flow Technology in Action
Thanks to the previous successful applications at the same site, engineers opted to retrofit an existing DN300 steel pipeline with a stationary clamp-on ultrasonic flow meter. This choice was based on a proven track record of performance in demanding industrial conditions.
Clamp-on systems offer key advantages, such as: installation without pipe modifications, no risk of contamination, zero pressure loss, and minimal maintenance. These benefits were particularly important given the volume and criticality of the water being measured. Â Â
Years earlier, a successful on-site demonstration – conducted under challenging conditions, including poor pipe surfaces and internal buildup – showcased the effectiveness of clamp-on ultrasonic flow technology. Since then, numerous clamp-on meters have been installed throughout the water management system, reliably measuring a wide range of media, including raw water, steam, condensate, and even gases such as ammonia.
Long-term Gains in Efficiency and Reliability
The retrofit was completed without any operational downtime, and the new setup introduced no energy loss or mechanical wear. For a facility managing such massive water volumes and energy loads, these small improvements translate into significant long-term gains.
Clamp-on ultrasonic flow measurement has evolved from a niche solution into a robust, industry-proven technology. In large-scale water systems where reliability, accuracy, and efficiency are essential, non-intrusive flow monitoring is now a cornerstone of sustainable infrastructure.
To find out more about the capabilities of clamp-on ultrasonic flow measurement in the chemical industry, or to discuss short or long-term portable flowmeter rental options, contact Simon Millington – Flexim | Emerson GB | flexim-uk@emerson.com | +44 (0)1606 781 420
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