Advanced Pipe Flow Monitoring with Electromagnetic Sensing

Flow Sense: Revolutionizing Pipe Flow Measurement with Electromagnetic Sensing

  • A client is a global leader in the manufacturing of industrial automation equipment. The client wanted to launch an innovative solution for a non-intrusive way of flow measurement using the electromagnetic flow measurement method.
  • The team consists of subject matter experts from the IIT institute, a Signal processing doctorate, an embedded engineer, and a Field application engineer who contributed to architecting and testing solutions.
  • Acclivis has evaluated and understood different theoretical solutions based on electromagnetic flow measurement methodology. Developed proof of concept, and prototype to test in Lab and on the field at a small scale.


  • Practical implementation of the theoretical concept of a non-intrusive way of measurement of flow through pipes using electromagnetic flow sensing methodology.


  • The challenge is to measure a signal which has a very low amplitude and consists of various noises.
  • It would be synonymous to say that signal is buried in noise that has similar frequencies.
  • It consists of different noises like Differential interference, In-phase interference, Common mode interference, Series mode interference (slurry), power noises, etc.

Client Benefits

  • Successful prototyping of theoretical concepts in electromagnetic flow measurement technology.
  • The system amplifies and identifies the precisely very low signal of interest from the highly noisy environment.
  • Provides clear differentiation and analysis for signal and noise with measurable markers.
  • The identified solution is reliable, reproducible, and scalable.
  • The system can be interfaced further with SCADA or an automation system.


  • The project was divided into two phases.
  • Phase 1- It includes the concept prototyping with Analog and digital methods. Initially, the differential signal is captured and amplified. Further, it fed to analog and digital signal processing pipelines for analysis and filtering. MATLAB was used in a digital path to analyze the frequency waveform from the captured signal. The signal is further processed using lock-in amplification and filters to remove noise. In the analog path, Lock-In Amplifier was used with the internal filtration and observed the waveform on the DSO.
  • Phase 2- The digital pipeline was replaced using a microcontroller base system. This noise-free signal information was sent to the cloud to observe the liquid flow in a system remotely.