Measuring the movement of fluids to control processes, ensure balance, and verify performance.
A flow sensor measures the rate at which a liquid or gas moves through a pipe, duct, or channel. Flow is a fundamental parameter that directly affects process efficiency, energy usage, material balance, and regulatory compliance.
Flow sensors operate by detecting changes caused by moving fluids, such as pressure drop, induced voltage, mechanical movement, or heat transfer. The detected effect is converted into an electrical signal proportional to flow rate.
The measured value directly represents the volumetric or mass flow rate of a fluid in a system.
Flow trends indirectly reveal leaks, blockages, pump or valve performance, process imbalance, and abnormal consumption patterns.
| Observed Flow Behaviour | What It Means in the Plant |
|---|---|
| Gradual flow reduction | Pipeline fouling, clogging, or valve restriction |
| Zero flow while pump is running | Dry run, air lock, or suction failure |
| Sudden flow increase | Pipe leakage, bypass opening, or valve failure |
| Highly fluctuating flow | Unstable process, cavitation, or control loop issue |
This sensor belongs to the Process Quality Cluster , where flow measurement enables mass load calculation, treatment performance evaluation, and regulatory compliance.
With Industrial IoT integration, flow sensors support remote monitoring, automated balancing, loss detection, consumption analytics, and regulatory reporting across distributed assets.
In process-quality applications, flow measurement enables mass load calculation by combining flow data with concentration values such as COD, BOD, TSS, and nutrient levels. This allows operators to quantify pollution loads in kg/day, optimize treatment performance, and meet regulatory discharge limits.
The Flow Sensor reveals how resources move through industry. It is essential for efficiency, accountability, and sustainability, converting invisible motion into measurable and actionable data.