Insertion Ultrasonic Flow Meter | Technical Support for Large‑Diameter Pipeline Measurement

Key Highlights

A. Hot‑tapping installation: Realise online installation without pipeline shutdown, suitable for non‑interruptible trunk pipelines

B. Wide pipe coverage: Support pipe diameter DN65‑DN6000, adapt to carbon steel, cast iron, PE, PVC and concrete pipes

C. Zero pressure drop: No moving parts inside pipeline, no extra flow resistance

D. Wide temperature adaptability: High‑temperature transducer supports medium temperature from ‑35℃ to 150℃

E. Built‑in data‑logger & heat measurement option: Record historical flow data; support thermal‑energy calculation with PT1000 sensors

F. RS485 Modbus‑RTU communication: Easy connection with DMA, NRW and SCADA remote monitoring systems

1. Working Principle & Core Advantages for Large‑Diameter Pipes

Insertion ultrasonic flow meters adopt the transit‑time ultrasonic measuring principle. Sensors are inserted into the pipeline interior through hot‑tapping fittings and make direct contact with the measured liquid. Unlike clamp‑on models that transmit ultrasonic signals through pipe walls, insertion probes capture flow velocity signals inside the pipeline, greatly reducing interferences from pipe material, rust and internal scaling.

This instrument supports pipe diameters ranging from DN65 up to DN6000, covering carbon steel, stainless steel, cast iron, PE, PVC and concrete pipelines. Equipped with a ball‑valve assembly, the probe can be inserted or retracted under full operating pressure without stopping pipeline flow. This hot‑tapped installation feature is extremely valuable for trunk pipelines that cannot be shut down, such as municipal water distribution networks, raw‑water delivery lines and agricultural irrigation main pipes.

There are no moving mechanical parts inside the pipe, which creates nearly zero pressure drop and lowers long‑term maintenance workload. The high‑temperature insertion transducer can work under medium temperatures from ‑35°C to 150°C, adapting to hot water, cooling water and various industrial process fluids. It also reserves heat measurement function when paired with PT1000 temperature sensors for energy consumption statistics in HVAC and power plant systems。

Table 1: Main Technical Specifications

Item	Specification
Pipe diameter range	DN65‑DN6000
Flow velocity	0.01‑12 m/s, bidirectional
Medium temperature	‑35℃ ~ 150℃ (high‑temp transducer)
Power supply	85‑265VAC / 24VDC optional
Communication	RS485 Modbus‑RTU
Display	3.5‑inch color LCD, 16‑key keypad
Key feature	Hot‑tapping installation, data‑logger, optional heat measurement

2. On‑site Installation Guidelines & Hot‑Tapping Operation

Correct installation directly determines measuring accuracy. Improper installation is the primary cause of measurement deviation. Avoid installation points close to turbulence sources such as pumps, elbows, reducers and regulating valves. For general conditions, keep minimum 10D straight pipe on upstream and 5D on downstream. For locations behind pumps or sharp elbows, extend upstream straight pipe to 15D. Do not install on pipe top with accumulated gas or pipe bottom with sediment. Reserve sufficient space for hot‑tapping drilling and later probe removal.

Standard hot‑tapping workflow:

1. Treat outer pipe surface → 2. Mount saddle base and full‑bore ball valve → 3. Complete pressure‑controlled drilling → 4. Retract drill bit, close valve and conduct leak test → 5. Insert probe and adjust insertion depth → 6. Align probe direction and tighten locking nut →7. Complete wiring and waterproof protection.

Outdoor cable joints must achieve IP67‑IP68 waterproof grade to prevent moisture damage.

3. Parameter Configuration and Communication Setup

After mechanical installation, complete parameter input on the TF1100‑EI flow converter. Incorrect pipe diameter value will result in large accumulated flow error. Users should fill in actual inner pipe diameter, wall thickness, pipe material and medium information.

For remote data transmission, configure RS485 Modbus‑RTU parameters including device address, baud rate and parity check. It supports data upload to DMA non‑revenue water management system or industrial SCADA platform. The built‑in data‑logger function saves historical flow data for review.

After setting is finished, ensure the pipeline is fully filled with liquid and check signal strength on LCD screen. Stable signal represents good installation status. Low signal usually points to wrong insertion depth, probe fouling or cable connection failure.

4. Routine Preventive Maintenance Suggestions

Maintenance frequency depends on measured medium. For clean tap‑water, inspect signal performance every 6‑12 months. For sewage and liquid with suspended solids, shorten inspection cycle to 3‑6 months.

Benefiting from ball‑valve structure, the probe can be pulled out under working pressure without pipeline shutdown for cleaning scaling and sediment. Please avoid scratching the ultrasonic sensing surface. Carry out zero‑point verification once per year. Conduct field comparative calibration if obvious measurement deviation occurs.

5. Common Field Troubleshooting

Fault Phenomenon	Possible Cause	Suggested Solution
Low ultrasonic signal strength	Probe surface fouling; loose or water‑infiltrated cable	Clean probe; check cable connection and waterproof treatment
Violent jumping flow readings	Turbulent flow, excessive bubbles, electromagnetic interference	Optimize installation position; separate signal cable from high‑voltage cable; improve grounding
Constant zero reading output	Pipe not fully filled; wrong probe orientation; incorrect pipe parameters	Guarantee full‑pipe condition; adjust probe direction; recheck pipe diameter settings

6. Typical Industry Application Scenarios

Insertion ultrasonic flow meters are widely used across multiple sectors.

• Municipal water supply: DMA district metering and non‑revenue‑water monitoring for large trunk pipelines, no pipe‑cutting required.
• Wastewater treatment plant: Inlet and outlet flow monitoring for sewage process.
• Agricultural irrigation: Water volume metering for main pipelines to support water‑saving management.
• Power, petrochemical and metallurgy: Circulating cooling‑water monitoring for energy efficiency audits.

Single‑channel sensor is fit for general monitoring scenarios. Select high‑accuracy configuration for custody‑transfer measurement, and high‑temperature probe for hot‑medium working conditions.