Electromagnetic Flow Measurement for Challenging Water Infrastructure Applications

ABB announced a major upgrade to the ProcessMaster FER620 electromagnetic flowmeter family to improve precision measurement capabilities in harsh industrial environments. The hardware iteration targets critical water infrastructure sectors, including pumping stations, water abstraction, treatment facilities, and irrigation systems, by introducing a fully welded and hermetically sealed sensor architecture.

Sensor Architecture and Ingress Protection
The upgraded measurement hardware features a rigid, fully welded sensor construction built to withstand continuous environmental exposure. The system carries an IP68 ingress protection rating, meaning the flowmeter is protected against continuous submersion in water. This design allows for the direct burial of the device into the ground without requiring a protective structural chamber, simplifying installation in remote or underground water distribution networks.

Velocity Measurement and Flow Dynamics
To address varying fluid dynamics, the sensor configuration utilizes a reduced bore design that enables highly accurate velocity measurements ranging from near zero up to 10 meters per second. This high turndown ratio ensures precise volume tracking during low-flow conditions, which is essential for capturing accurate data during night flow rates when industrial and municipal water consumption drops significantly.




Pipeline Integration and Modular Lifecycle Management
Space constraints in municipal pipe layouts require specific measurement solutions that do not depend on long, straight sections of pipeline to stabilize water flow. The flowmeter utilizes a 0xD/0xD installation profile, meaning it requires zero straight pipe clearance either upstream or downstream from the sensor unit. Krishna Prashanth, Global Product Line Manager for Electromagnetic Flowmeters at ABB, noted that the equipment's capacity to maintain accuracy in challenging scenarios with limited straight-run piping enables its deployment across the full water cycle.

The device incorporates a modular architecture, allowing operators to adapt internal components to shifting technological and operational requirements without overhauling the entire pipeline installation. This lowers the total cost of ownership and reduces industrial waste going to landfills. Furthermore, the system integrates high-speed IoT connectivity across all models, establishing remote data transmission for centralized process control and enhanced asset analytics.

Additional Context:
This section details technical specifications and competitive benchmarking not included in the original product announcement

Within the industrial flow measurement sector, electromagnetic flowmeters are routinely evaluated against ultrasonic and Coriolis metering technologies. Electromagnetic models rely on Faraday's Law of Induction and require conductive fluids to operate, making them highly effective for municipal water but unsuitable for hydrocarbons. Compared to clamp-on ultrasonic meters, full-bore electromagnetic sensors provide superior volumetric accuracy under disturbed flow profiles. The 0xD/0xD installation capability represents a measurable physical advantage over standard electromagnetic meters, which typically require upstream clearances of three to five pipe diameters to stabilize fluid turbulence before measurement can accurately occur.

Edited by Natania Lyngdoh, Induportals editor, assisted by AI.

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