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Insertion Electromagnetic Flowmeter

Cost-effective flow measurement for medium-to-large diameter pipelines—this flowmeter inserts through a ball valve into existing pipes from DN100 to DN3000 without system shutdown or pipe cutting. Unlike full-bore electromagnetic flowmeters that require costly removal and reinstallation, the insertion design enables hot-tap installation under pressure, measures flow at the optimal velocity point, and delivers ±1.5% to ±2.5% accuracy at a fraction of the cost—ideal for retrofitting water treatment plants, industrial process lines, and municipal distribution networks where downtime is prohibitive and full-bore meters are economically impractical.
  • Pipe Size: DN100 – DN3000
  • Flow Accuracy: ±1.5% / ±2.0% / ±2.5% (selectable)
  • Velocity Range: 1 – 10 m/s (continuously adjustable)
  • Temperature: -25°C to +80°C
  • Pressure: 0.6 – 1.6 MPa
  • Protection: IP65/IP67/IP68 sensor (optional) | IP65 converter
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Large-Pipe Flow Measurement Without the Large-Pipe Cost

Five reasons insertion design outperforms full-bore flowmeters for medium and large-diameter applications

nstall on Live Pipelines Without System Shutdown

Ball valve mounting assembly (threaded or flanged type) allows sensor insertion and removal under operating pressure up to 1.6 MPa. No pipe cutting, no welding flanges, no process interruption—install in 2-3 hours versus days of downtime for full-bore meter installation. Particularly valuable for water treatment plants, refineries, and municipal systems where shutdown costs exceed equipment costs.

  • Zero downtime installation—system remains fully operational during meter commissioning

Reduce Capital Cost by 60-75% Compared to Full-Bore Meters

For large-diameter pipelines (DN500-DN3000), full-bore electromagnetic flowmeters require expensive large-bore sensors, heavy flanged sections, and specialized lifting equipment for installation. Insertion design uses a compact sensor—regardless of pipe size—dramatically reducing both equipment cost and installation labor for the same measurement accuracy.

  • Same measurement performance at a fraction of the cost for pipes >DN400

Achieve ±1.5% to ±2.5% Accuracy Through Optimized Velocity Point Measurement

Sensor positions at either pipe centerline (DN<400) or 0.121D from wall (DN≥400) to measure flow at the optimal velocity point. Proven velocity-area calculation method converts point measurement to total volumetric flow. Unaffected by variations in temperature, pressure, density, or viscosity—maintains accuracy across changing process conditions. Three accuracy classes available to match application requirements and budget.

  • Selectable accuracy grades for optimal cost-performance balance

Battery-Powered Option for Remote Sites Without Infrastructure

For DN100-DN1000 installations at remote pump stations, irrigation control points, or temporary metering applications, 3.6V battery power option provides 1-2 years continuous operation without external power supply. Eliminates costly AC wiring installation and enables rapid deployment for temporary measurement campaigns or isolated monitoring points.

  • Off-grid measurement capability—no power infrastructure required

Service and Verify Without System Depressurization

Retractable design allows sensor withdrawal through isolation ball valve for inspection, cleaning, or verification—without draining the pipeline or interrupting flow. Quarterly verification programs and annual calibration checks become practical routine procedures rather than major maintenance events requiring extended outages. Simple threaded or flanged ball valve options suit different pipe sizes and pressure ratings.

  • Maintenance windows reduced from days to hours—no system shutdown required
Parameter
Specification
Measurement Principle
Electromagnetic (Faraday's Law) - point velocity measurement
Pipe Size Range
DN100 – DN3000 (closed pipeline applications)
Flow Accuracy
±1.5% / ±2.0% / ±2.5% of reading (selectable accuracy classes)
Velocity Range
1 – 10 m/s (continuously adjustable full scale)
Fluid Temperature
-25°C to +80°C
Operating Pressure
0.6 – 1.6 MPa
Sensor Body Material
304 or 316 stainless steel (optional)
Liner Materials
ABS (standard), PTFE (optional for chemical resistance)
Electrode Materials
316L, Hastelloy B, Hastelloy C, Titanium, Tantalum, Platinum-Iridium, Tungsten Carbide Coated
Power Supply Options
85-250V AC (45-63Hz), 20-36V DC, 3.6V Battery (DN100-DN1000 only)
Output Signals
4-20mA, Frequency, Pulse, RS485 Modbus
Communication Protocols
Modbus RTU (standard) | HART (optional) | Profibus DP (optional)
Protection Rating
Sensor: IP65 / IP67 / IP68 (selectable) | Converter: IP65
Display
Digital display: flow rate, velocity, totalized volume
Excitation Mode
Low-frequency square wave excitation
Configuration Options
Integrated type (sensor + converter combined), Split type (remote converter)
Explosion-Proof
SIL-3 Certification
Quality Standards
CE Certification

Liner & Electrode Material Selection Guide

Sensor Materials for Process Compatibility

Select liner and electrode materials matched to fluid chemistry and temperature

Liner Materials Table:

Lining Material
Temperature Range
Best Applications
ABS Plastic
-25°C to +80°C
Standard sensor head material - cost-effective for most water, wastewater, and neutral process fluids
PTFE
-25°C to +80°C
Strong acids, alkalis, organic solvents, high-purity chemicals requiring non-contaminating contact

Electrode Materials Table:

Electrode Material
Corrosion Resistance
Typical Applications
316L Stainless Steel
General purpose, moderate corrosion resistance
Potable water, municipal wastewater, neutral industrial process water, cooling water
Hastelloy B
Excellent for non-oxidizing acids
Hydrochloric acid (all concentrations), reducing chemical environments
Hastelloy C
Superior for oxidizing acids and chlorides
Sulfuric acid, chromic acid, ferric chloride, wet chlorine, hypochlorite solutions
Tantalum
Excellent for chlorides and seawater
Seawater, brackish water, sodium hypochlorite, brine, desalination plants
Tantalum
Extreme corrosion resistance
Highly corrosive acids, pharmaceutical chemicals, HCl/H₂SO₄ mixtures, aqua regia
Platinum-Iridium Alloy
Universal chemical resistance
Ultra-pure water systems, semiconductor manufacturing, research laboratories
Tungsten Carbide Coated Stainless Steel
Erosion resistance for abrasive fluids
Slurries, wastewater with suspended solids, fluids containing sand or particulates

Note: Electrode material selection critical for long-term reliability. Contact factory for fluid compatibility guidance.

Protection Class Section:

  • IP65 (Standard – Converter & Basic Sensor): Dust-tight, protected against water jets—suitable for indoor installations and weather-protected outdoor location

  • IP67 (Optional – Sensor): Dust-tight, withstands temporary immersion up to 1 meter—suitable for installations subject to occasional flooding or spray washdown

  • IP68 (Optional – Sensor): Dust-tight, continuous submersion rated—suitable for underground wet wells, permanently submerged installations, flood-prone environments

Optimized for Medium and Large-Diameter Flow Measurement

Cost-effective metering where full-bore flowmeters are economically impractical

  • Municipal Water & Wastewater

    • Water treatment plant process monitoring
    • Distribution main flow measurement
    • Wastewater influent/effluent metering
    • Pumping station performance monitoring
    • Large-diameter trunk sewers
    • Water balance and loss detection programs

  • Chemical & Industrial Processing

    • Large-diameter process water lines
    • Cooling water circulation systems (DN400-DN3000)
    • Reactor feed and discharge lines
    • Chemical transfer pipelines
    • Inter-plant transfer metering
    • Process cooling and heating loops

  • Power Generation & HVAC

    • Condenser cooling water flow
    • Circulating water pump monitoring
    • Boiler feed water measurement
    • Chilled water plant monitoring (DN500-DN2000)
    • District heating/cooling systems
    • Thermal power plant process water

  • Irrigation & Agricultural Water

    • Main irrigation line flow measurement
    • Agricultural water district metering
    • Water rights allocation and monitoring
    • Large-diameter canal and ditch flow
    • Reservoir discharge measurement
    • Groundwater pumping station flow

  • Mining & Construction Dewatering

    • Mine water pumping systems
    • Mine water pumping systems
    • Quarry water management
    • Tailings transfer pipelines (with tungsten carbide electrodes)
    • Underground water drainage
    • Remote pit dewatering stations (battery-powered)

Simple Installation for Existing Pipelines

Retrofit capability without system modification or extended downtime

 

1. Installation Structure Options

 

  • Simple Type: Direct insertion through welded mounting base. Most economical option for new installations or retrofit projects where ball valve can be installed during scheduled shutdown.

 

  • Threaded Ball Valve Type: DN50 threaded ball valve assembly. Suitable for smaller pipe sizes (DN100-DN600) and lower-pressure applications. Enables sensor removal for maintenance without complete valve disassembly.

 

  • Flanged Ball Valve Type: Full-flanged DN50 ball valve with standard ANSI/DIN flange connections. Preferred for larger pipes (DN600-DN3000) and higher-pressure applications up to 1.6 MPa. Available in both integrated type (sensor and converter combined) and split type (remote converter mounting) configurations.

 

 

2. Critical Installation Requirements

 

Reduced Straight Pipe Requirements

 

Unlike many flowmeter types requiring 10D-20D straight pipe, insertion electromagnetic flowmeters need only:

 

  • 5DN upstream (where N = nominal diameter in mm)
  • 3DN downstream
  • For installations after pumps, valves, or double bends, increase to 10DN upstream when possible

 

Sensor Orientation

 

Directional indicator arm must align with flow direction within ±5°. Magnetic field, flow velocity, and electrode axis must be mutually perpendicular per Faraday’s law. Incorrect orientation causes systematic measurement error.

 

Grounding For metallic pipes:

 

Ground sensor through pipe flange connection. Verify electrical continuity between sensor body (304/316 SS) and pipe. For non-metallic or lined pipes: Install grounding electrode. Connect to sensor ground terminal (Terminal C). Maintain grounding resistance <10Ω.

 

Configuration Selection

 

  • Integrated Type: Sensor and converter form single unit. Simplifies installation, reduces cable connections. Suitable when converter can be mounted at pipe location.

 

  • Split Type: Remote converter mounting up to 50m from sensor. Preferred when:
    1. Pipe location is inaccessible or hazardous
    2. Converter needs protection from weather/vibration
    3. Multiple sensors controlled from central location
    4. Existing control room infrastructure available

Ready to Reduce Your Large-Pipe Metering Costs?

Our application engineers will help you determine optimal sensor positioning, accuracy class selection, and configuration requirements for your specific pipeline.
info@hbmeter.cc
(+86) 152-3780-0315
1 Jingsan North Road, Xiangfu District, Kaifeng, Henan 475004 China

About HBmeter

AFT Instruments is a high-tech manufacturer delivering precision flow instrumentation for water, chemical, power, industrial automation, and process industries.
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info@hbmeter.cc
(+86) 152-3780-0315
(+86) 152-3780-0315

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