Insacal Flow Rig is designed for on-site, in-line calibration of flowmeters, eliminating the need for laboratory calibration and extended production downtime. This section explains the fundamental principles behind in-line flow calibration using the Insacal Flow Rig.
The flow calibration rig is easily connected to the Unit Under Test (UUT). Water is circulated through both, and the readings are compared. Calibration can be performed using as many points as needed, and the rig supports both creating and following your Standard Operating Procedures, making your quality control significantly more reliable.
As an added benefit, the in-line calibration verifies your flow meter directly under process conditions, eliminating uncertainties that may arise when removing and reinstalling a flow meter.
Plug-and-Play Connection to the Process
Insacal Flow Rig operates by connecting directly to pre-installed flanged pipework on either side of the UUT. This can be done using either flanges or Tri-Clamps. Measurement data from the UUT can be collected directly via mA and pulse signals.
Achieving Highly Accurate and Stable Calibration
After being connected to the UUT, calibration can begin. During the calibration, water from the rig’s tank is circulated through both the UUT and the master meter, and the readings are compared. The flow calibration rig uses highly accurate, state-of-the-art Coriolis mass flow meters to ensure precise measurement of the flow.
Ensuring Repeatability with Standard Operating Procedures
The rig can apply as many calibration points as needed, allowing you to calibrate each measuring point in accordance with your internal Standard Operating Procedures (SOPs).
Using SOPs results in an optimised calibration that closely reflects actual process conditions, thereby making your quality control significantly more reliable. This also ensures that each dosage stays within batch specifications, resulting in consistent product quality and giving you full control over valuable, high-cost ingredients – ultimately helping to optimise production costs.
Verification of the Complete Test Loop
Because the rig is connected directly to the process pipework, it verifies the entire test loop—not only the meter itself. This is a key advantage over laboratory calibration, where conditions differ from the production environment. In-line verification ensures that no new uncertainties are introduced when reinstalling the flow meter. As the meter never leaves the production string, the risk of contamination is also significantly reduced.
Built-in Troubleshooting Capability
The rig can also be used to diagnose suspected measurement issues. By comparing readings directly in-line, operators can quickly confirm whether discrepancies originate from the flow meter or elsewhere in the process setup.
