Traditional Flow Measurement Technologies in a Digital World

The advent of AI, machine learning, and condition-based monitoring (CBM) is revolutionising various industries, including flow measurement. With these advancements, will traditional flow measurement systems like orifice plates, pressure differential (PD) meters, and turbine meters become obsolete?

In a May 2024 webinar sponsored by the UK Government's Department of Science, Innovation, and Technology (DSIT), experts from TÜV SÜD and academia discussed whether metrology is keeping pace with this growing need and what is required to achieve it. Read the summary of the discussion below or watch the full panel discussion to get all the insights from our experts on this topic and other thought-provoking questions in the webinar recording (Question 3: Timestamp 33:00).

With the latest developments in AI, machine learning, and CBM, how will they influence the development and adoption of certain flow measurement systems? For example, is there still going to be a place for the humble orifice plate, PD meter, and turbine meter, etc, in the future? And how might these traditional methods evolve to remain relevant in modern applications?

TÜV SÜD Senior Consultant, Dr Chris Mills, was the first to respond, emphasising that traditional technologies still have a significant role to play. "When we’re designing our own metering system, to be our secondary reference system to our primary, the flow meters that we often select are traditional flow meters," he said. Chris highlighted the reliability and confidence that traditional meters like PD meters, turbine meters, and differential pressure devices offer.

He also expressed the opinion that AI could revolutionise flow meter diagnostics by:

1. Engaging in real-time conversations with users
2. Identifying issues and guiding troubleshooting
3. Recommending next steps based on previous actions
4. Advising on calibration needs

This AI-driven approach could be the next development in flow meter diagnostics and usage, but Chris believes that traditional flow meters still have a significant role, especially in metrology:

1. Used in designing secondary reference systems for national metrology institutes
2. Preferred for their stability, repeatability, and reproducibility
3. Backed by extensive historical data and user confidence
4. Commonly chosen as transfer standards in international comparisons (eg turbine, PD, or differential pressure devices)

Their reliability and consistent performance make traditional flow meters valuable in both laboratory and comparative settings.

Advancements in Traditional Flow Measurement Technologies

Dr Gabriele Chinello, TÜV SÜD's CCUS lead, believes that the orifice plate, despite its simplicity, remains a popular flow meter, comprising a significant portion of installed meters. Having read that approximately 40% of installed meters are DP meters, he stated that we still need ways to calibrate and maintain them. Recent advancements in DP meters have improved their diagnostic capabilities, with software now available to extract valuable information from DP signals. While AI and machine learning offer potential in condition-based monitoring, the focus should remain on traceability, validation, certification, and standardisation in flow metering.

Cost-Effectiveness and Practical Applications

TÜV SÜD expert in hydrogen fluid flow measurement, Dr Piotr Traczykowski added a practical viewpoint, emphasising the cost and application-specific nature of flow measurement technologies. He noted that while Coriolis meters are convenient, they might not be the most cost-effective solution for all applications. "It’s up to your application. I like Coriolis meters, but on the other hand, if I have pure water, a turbine is fine," he said.

Sonic nozzles are mechanically simple, requiring only pressure and temperature sensors, and less electricity than Coriolis meters. Although they need occasional calibration, they provide necessary data and can serve as an additional standard. For instance, refuelling stations can use them as a parallel line when their primary flow meter is being calibrated.

Simple devices won't become obsolete despite modern alternatives. Their continued use will be determined by cost-effectiveness and specific applications.

Losing Traditional Flow Measurement Knowledge

Professor Manus Henry, Professor of Flow Measurement at Coventry University and the University of Oxford, and Chair of the National Measurement System's Flow Programme Expert Group (PEG), offered a more cynical view. He noted that flow measurement always requires some form of mechanical interaction, even with advanced technologies. Low-cost mechanical technologies might see renewed interest when combined with sophisticated software to compensate for their limitations. This could be particularly relevant in the energy transition, where many new flow meters are needed.

He warned, however, that the detailed knowledge of these technologies may be lost if we rely too heavily on AI interpretation. The challenge lies in balancing the use of AI for routine tasks while maintaining the fundamental skills and judgment needed in the field.

So, in my opinion there is a future for traditional flow measurement technologies. While digital advancements are shaping the industry, traditional technologies still offer reliability, cost-effectiveness, and ease of use. The key lies in integrating modern diagnostic capabilities and enhancing them with AI and machine learning to improve these traditional systems.

Watch the full panel discussion of this question in the webinar recording (Timestamp 33:00)

PANELLISTS

Professor Manus Henry, Professor of Flow Measurement at Coventry University and the University of Oxford.

Professor Henry is also chair of the National Measurement System’s Flow Programme Expert Group.

Dr Chris Mills, Senior Consultant, TÜV SÜD

Chris is an expert in Coriolis meters and active in many flow measurement technical committees and the development of several ISO metering standards.

Dr Gabriele Chinello, Head of CCUS, TÜV SÜD

Gabriele is also a technical advisor on CCUS metering to the UK Department of Energy Security and Net Zero (DESNZ) as well as participating in various ISO and BSI committees.

Dr Piotr Traczykowski, Clean Fuels Consultant TÜV SÜD

Piotr is heavily involved in hydrogen metrology and accurate measurements of hydrogen dispensed by hydrogen refuelling stations.

MODERATOR

Colin Lightbody, Principal Consultant, TÜV SÜD

If you are involved in flow measurement, consider a balanced approach that leverages both traditional and modern technologies. Stay updated with the latest advancements in diagnostics and AI to enhance the reliability and efficiency of your systems. Our flow measurement and condition-based monitoring (CBM) experts will be happy to discuss the best solutions for your business so contact us today.

Read the other blog posts from this webinar about The Evolution of Metrology in the Energy Transition and Traditional Time-Based vs. Modern Condition-Based Calibration in Metrology.

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