Processplus were tasked by the client to investigate a suspect inlet flowmeter. Following a thorough assessment, we reported that the flowmeter was indeed faulty and required replacement. At the same time, we provided a fully costed engineering solution for accurate flow measurement in a partially filled pipe.

Our solution utilised the Nivus POA pipe insertion flow velocity sensor to measure the influent speed, along with an ultrasonic level transducer to monitor its depth. Using these key parameters and process data input into the Nivus transmitter, the system can accurately calculate the flow rate within the partially filled pipe.

To install these instruments, Processplus designed and procured a bespoke spool piece, manufactured to match the size of the existing flowmeter. This ensured the new assembly could be installed without the need for pipe modifications—streamlining the installation process and reducing site downtime. The client arranged over-pumping while we isolated the pipeline and replaced the faulty meter. Within just two hours of shutdown, the new flowmeter was installed, and the pipeline brought back online—a fantastic effort by the team.

As part of the overall solution, we also supplied and installed a new sump pump with a float switch to prevent future flooding of the chamber. Additionally, new cable containment was fitted.

Following commissioning, the flow signal was successfully verified on the site’s SCADA system.

This project highlights our capability to deliver ‘engineering from conception to completion’: designed, managed, and delivered by the Processplus team, in collaboration with Nivus and their outstanding flow instrumentation.

If you or your business requires a solution to a projects problem, get in touch with our team to discuss how we can help overcome any challanges!