While accurate installation is the foundation of flow meter performance, ongoing management and calibration are the keys to maintaining long-term accuracy in large-diameter water meters. Based on field experience and case studies, we summarize ten common issues and share practical tips for online calibration and traceability.

Top 10 Flow Meter Management Issues

• Incorrect calibration coefficient between the converter and the pipeline exit.

• Power outages interrupt the reading of electromagnetic and ultrasonic meters, both of which require continuous power.

• Open-air installation increases risk of moisture, temperature fluctuation, and vandalism.

• Data management loopholes: lack of traceability or missing baseline datasets.

• Failure to inspect regularly or verify data with standards.

• Water seepage in the instrument chamber damages sensors over time.

• Installation above pipeline high point leads to bubble accumulation and partial pipe flow.

• Electromagnetic interference from pumps and power lines distorts readings.

• Vibration displacement of clamp-on ultrasonic probes reduces accuracy.

• Internal fouling in electromagnetic sensors causes metering drift.

Challenges in Flow Meter Calibration

Removing large-caliber flow meters for recalibration is often impractical or economically unfeasible, especially in buried or high-flow pipelines. Therefore, online calibration and fixed-point verification methods are becoming mainstream.

Recommended Calibration Strategy:

• Use a high-precision clamp-on ultrasonic flowmeter as a reference meter to verify the installed meter’s readings.

• Ensure the same pipe diameter and matching transducer type between lab tests and field conditions.

• For electromagnetic meters, organize joint on-site calibration with:

• Experienced metrology technicians,

• Third-party verification specialists,

• Recently calibrated standard reference meters.

Just like calipers and tape measures in precision manufacturing, different flow meters can calibrate each other under fixed conditions and common flow points.

➡ Need to calibrate an installed flow meter? See our online calibration solutions

Conclusion: Reliable Metering Requires Reliable Oversight

Water plants must treat flow meter management as a long-term task, not a one-time event. From installation quality to scheduled calibration and data backup, every step counts. Ensuring the long-term traceability and performance of large-diameter flow meters will directly enhance the operational transparency and efficiency of water supply enterprises.

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