📋 Case Study

Flow Measurement Optimization for Municipal Water Treatment Plant

Inconsistent flow readings during low-flow conditions; inability to detect electrode fouling or liner degradation

🏗️ Project Overview

Retrofit of aging electromagnetic flowmeters across 3 filtration lines in Toronto

🎯 Challenge

Inconsistent flow readings during low-flow conditions; inability to detect electrode fouling or liner degradation

🔧 Design Approach

Replaced with smart magmeters featuring built-in diagnostics (electrode resistance monitoring, empty pipe detection, coating thickness estimation)

📐 Design Diagram

_min = 0.012 m³/h R_coating = 1.35×R_baseline Process flow Electrodes Liner Challenge

AI-generated project design illustration

📐 Key Calculations

Minimum Detectable Flow Rate

Qmin = k·√(Re_min·ν·D)

Result: 0.012 m³/h

Enabled accurate dosing control at low flows

Coating Thickness Threshold

R_coating = R_baseline × 1.35

Result: 1.35× baseline

Triggered maintenance alert before accuracy loss >1%

📊 Results

Eliminated 100% of false low-flow alarms; reduced chemical overdosing by 18%; predictive maintenance alerts cut unplanned downtime by 72%

💡 Lessons Learned

• •Baseline electrode resistance must be captured during commissioning
• •Diagnostic thresholds require site-specific validation

✅ Key Takeaways

• 1Baseline electrode resistance must be captured during commissioning
• 2Diagnostic thresholds require site-specific validation