Insertion ultrasonic flowmeter
Keywords: jujea ultrasonic flowmeter, insertion flowmeter, DN500 carbon steel pipe flowmeter, water flow measurement, Brazilian flowmeter project
In the field of industrial flow measurement, large-diameter carbon steel pipes, rusty surfaces, and the need for accurate water flow data together pose a huge challenge. In October 2025, professional flowmeter manufacturer jujea, with its insertion ultrasonic flowmeter, successfully provided a customized solution for a Brazilian customer who had difficulties in measuring water flow in a DN500 carbon steel pipe, overcoming the obstacles caused by rust and ensuring measurement accuracy.
How did the Brazilian customer choose a flowmeter?
This Brazilian customer is engaged in industrial water supply and distribution. Accurate measurement of water flow in a DN500 carbon steel pipe is crucial to its production and resource management. However, several problems arose in the initial measurement attempt:
(1) Pipeline and medium characteristics
The pipe involved was DN500 and made of carbon steel. Due to time and environmental factors, the inner and outer surfaces of the pipe were rusted. The measuring medium is water, which is clear in itself, but it has to flow through this rusty pipe.
(2) Limitations of external probes Initially
The customer tried to use an external ultrasonic flowmeter probe. However, the rust on the carbon steel pipe seriously affected the transmission of ultrasonic waves. The rust layer formed an uneven and discontinuous surface, which caused ultrasonic signal scattering, irregular reflection and significant attenuation. As a result, the measurement accuracy was far from satisfactory, the error was high, and it was impossible to provide reliable flow data for production scheduling and resource allocation.
(3) Specific requirements of the project
The customer had clear and specific requirements for the flowmeter: - It should be suitable for DN500 pipes to accurately measure water flow. - The installation method should be plug-in, because the external probe was not effective due to rust. - All necessary connectors for welding to the pipe must be included. - The flowmeter should support RS485 communication using MODBUS-RTU protocol for seamless integration with the customer's existing control system. - It needs to be airlifted to Brazil to ensure timely delivery.
2. JUJEA's Insertion Ultrasonic Flowmeter Solution
As a veteran flowmeter manufacturer with independent R&D capabilities, JUJEA analyzed the customer's pain points and proposed a targeted solution centered around its insertion ultrasonic flowmeter.
(1) Core Product Parameters
The JUJEA insertion ultrasonic flowmeter selected for this project has excellent performance parameters that perfectly match the customer's needs:
| Parameter Category |
Specific specifications |
Advantages |
| Accuracy |
±1.5% |
Meet customer requirements for precise flow measurement and ensure that the error range is within the acceptable range for industrial applications. |
| power supply |
24VDC and 240VAC |
Offers flexible power supply options, compatible with various power supply configurations commonly found in industrial environments. |
| Signal output |
4 - 20mA ~ RS485 (supports MODBUS - RTU protocol) |
Achieve smooth data transmission with customer control systems, facilitating real-time monitoring and remote management of water flow. |
| Installation |
Plug-in |
Overcoming the limitations of external probes, it is directly inserted into the pipe, avoiding surfaces affected by rust and ensuring stable transmission of ultrasonic signals. |
| Pipe size compatibility |
Applicable to DN500 pipes (pipe wall thickness within 15mm) |
Specially designed for customers' DN500 carbon steel pipes, ensuring a proper and secure installation. |
| Material |
High-quality stainless steel probe |
Resistant to water and micro-corrosion environments caused by rust, ensuring long-term stable operation. |
(2) Manufacturer’s advantages in customization and production As a manufacturer.
JUJEA has full control over the entire production process from design to delivery: - Customization: Based on the customer’s requirements for plug-in installation and compatibility with DN500 pipes, JUJEA adjusted the probe length and mounting accessories. The connectors required for welding to the pipe were also customized to ensure a perfect fit with the customer’s pipe. - Quality control: Each flow meter undergoes a rigorous quality inspection process. From the selection of raw materials to final assembly, JUJEA ensures that each component meets high quality standards. The plug-in probe is tested for ultrasonic transmission efficiency and durability to ensure reliable operation in rusty pipe environments. - Timely delivery: With its own production facilities, JUJEA is able to speed up the production process and arrange air transportation to Brazil as required by the customer, ensuring that the flow meter is delivered to the customer in time for installation and commissioning.
3. Flow measurement project implementation and results
(1) Installation and debugging
After receiving the JUJEA plug-in ultrasonic flow meter, the customer’s technical team proceeded to install it. The process went very smoothly:
First, the designated location of the DN500 carbon steel pipe was prepared and the custom-made connector was securely welded.
Then, the insertion probe was inserted into the pipe through the connector. The design of the probe ensured a tight seal to prevent water leaks.
Finally, the flow meter's transmitter was connected to the power supply and the customer's control system. JUJEA's technical support team provided remote guidance throughout the commissioning process, helping the customer set the relevant parameters and verifying the communication via RS485 using the MODBUS-RTU protocol.
(2) Significant results
Since the successful installation and commissioning of the JUJEA insertion ultrasonic flow meter, the customer has achieved significant results:
Accurate measurement: Provided the customer with reliable water flow data. The measurement data enabled the customer to optimize water use, reduce waste, and improve production efficiency.
Stable operation: Even in the rusty DN500 carbon steel pipe, the insertion probe ensured stable transmission of the ultrasonic signal. The flow meter continued to operate without measurement errors or equipment failures caused by rust on the pipe surface. - Seamless System Integration: RS485 communication using the MODBUS-RTU protocol enables flow meter data to be seamlessly integrated into the customer's control system. The customer can now monitor water flow in real time, set alarms for abnormal flow conditions, and generate detailed flow reports for analysis.
Cost-Effectiveness: By solving measurement problems with a cost-effective insertion flow meter, the customer avoided the need to replace expensive pipes or use a more complex and costly measurement system. The total cost, including the flow meter and air freight, was within the customer's budget and offered excellent value for money.
4.JUJEA's Commitment as a Manufacturer
The success of the Brazilian project further demonstrates JUJEA's strength as a flow meter manufacturer. JUJEA is committed to:
Continuous Innovation: Investing in R&D to improve flow meter technology, particularly in addressing challenging measurement scenarios such as rusty pipes, different pipe materials, and various flow media.
Customer-Centric Service: Providing customized solutions based on each customer's unique needs and providing technical support at every stage of the project lifecycle, from initial consultation to after-sales service. - Global Reach: Expanding its global market share ensures that customers from diverse countries and industries can benefit from JUJEA's high-quality flowmeters and professional services.
In summary, the successful application of JUJEA's insertion ultrasonic flowmeter in a Brazilian client's rusted DN500 carbon steel pipeline project demonstrates the manufacturer's ability to solve complex flow measurement problems. With advanced technology, reliable
products, and a customer-oriented approach, JUJEA will continue to provide flow measurement solutions to plants worldwide.
Contact Information: For customized flowmeter solutions tailored to your specific pipeline and media conditions, please visit JUJEA's official website at
www.jujea-tech.com or contact our international service hotline for a free consultation and quote.
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