Flow Measurement of Water in Utility Water System at Power Plant
Monitoring Raw Water Flow and Consumption in Plant Utility Network Without Shutdown / any physical intrusion into the pipe or interruption of the process
Product Installed
SBEM’s 153 UCW – Clamp-On Ultrasonic Flow Mete
Application Location
Water Management in Utility Water System
Industry
Power Plant
Background
In any power plant, water is one of the most critical resources used across multiple processes, from cooling systems, ash handling, and boiler feed to general cleaning and dust suppression. Managing and monitoring the flow and usage of utility water is vital to ensure operational efficiency, maintain sustainability goals, and prevent water loss.
At the Power Plant, the utility water network distributes water from the main feed line to various plant areas, including the MGR unloading and BULB zones, where raw water is required for multiple operational activities.
However, the power plant faced a recurring challenge, inadequate visibility of actual flow and consumption of raw water at these specific locations. Without precise monitoring, it was difficult to evaluate usage trends, detect inefficiencies, or identify possible leakages in the distribution network.
This created an urgent need for a reliable and maintenance-free flow measurement system that could provide accurate, real-time data without interrupting plant operations.
Requirement
The power plant’s maintenance and utility teams needed a system that could:
- Measure live flow rate and total water consumption continuously.
- Work effectively on raw water lines with varying quality and suspended particles.
- Be installed without cutting the existing pipe or halting the process.
- Offer high accuracy even under fluctuating flow conditions.
- Communicate data to the central SCADA system for monitoring and analysis.
Since the plant’s utility line was part of a continuous process, any shutdown or pipe modification would have impacted operations and increased downtime. Therefore, a non-intrusive flow measurement solution was essential.
Product Installed
SBEM Instruments provided the 153 UCW – Ultrasonic Clamp-On Flow Meter, an ideal solution for this application.
The UCW series uses transit-time ultrasonic technology, which measures flow velocity by detecting the time difference between ultrasonic pulses transmitted upstream and downstream through the pipe wall.
This advanced technology enables accurate flow measurement without any physical intrusion into the pipe or interruption of the process. The 153 UCW can be mounted externally, even on large-diameter pipes carrying raw or treated water, making it perfect for the utility water system at the power plant.
SBEM’s engineering team coordinated with the plant personnel to select the right sensor configuration, perform site calibration, and ensure data accuracy. The system was then seamlessly integrated with the SBEM-provided SCADA platform, enabling the operators to view real-time flow trends, daily consumption reports, and performance insights directly from the control room.
Technology Used
Ultrasonic Transit-Time Technology
- Measures flow by calculating the difference in time taken by ultrasonic pulses traveling in and against the direction of flow.
- Ensures high accuracy and reliability even in variable flow conditions.
- Non-contact measurement, ideal for applications where pipe cutting is not possible.
Digital Communication
- Integrated MODBUS / RS485 communication allows easy connectivity with SCADA.
SCADA Integration
- The flow data from the UCW meter is transmitted to the SBEM SCADA system for continuous monitoring, recording, and trend analysis.
- Operators can monitor instantaneous flow, total consumption, and historical patterns to improve plant water management.
Customer Benefits
- Non-Intrusive Installation: No need to cut the pipe, close valves, or empty the line installation completed without any plant shutdown.
- Real-Time Visibility: Continuous live monitoring of flow and consumption across the utility water network.
- Accuracy & Reliability: Precise readings even under varying flow or pressure conditions.
- SCADA Connectivity: Centralized data visualization, trend logging, and report generation through SBEM’s SCADA platform.
- Reduced Maintenance: No moving parts, ensuring minimal upkeep and long service life.
- Improved Water Management: Enables better decision-making for resource optimization and leak detection.
- Cost Savings: Prevents unplanned downtime and unnecessary water wastage.
Outcome
After installation, the power plant achieved complete visibility over water usage within its utility system. The UCW flow meter allowed engineers to track consumption trends, identify anomalies, and ensure efficient utilization of raw water resources.
With data now available in real-time through the integrated SCADA platform, the plant was able to take data-driven decisions that supported sustainability goals and improved operational reliability.
This installation further reinforces SBEM’s role as “Your Measurement Partner” , delivering solutions that are Reliable Beyond Measure and showcasing Indianeering Excellence in every project.