Flow, level & control
OPTIMISING HYDRAULIC PERFORMANCE: OVERCOMING CHALLENGES OF PRECISION FLOW MEASUREMENT
Titan Enterprises shares key insights to help engineers and operators navigate challenges of precision flow metering to ensure accurate measurements and safe process operations.
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etering liquids under pressure may seem straightforward at first glance - install a flowmeter in the product line, connect it to an instrument, control the
measurement with on-board software, wire in a valve and pump, and switch the flow system on. However, real-world applications reveal a host of complexities that must be addressed to achieve precise and repeatable results. Today’s advanced process and fluid handling systems demand highly precise flow measurement, and even slight inconsistencies in system design can lead to inaccuracies, wasted product, or disrupted processes. Where hydraulic systems are concerned, flowmeters play a critical role in maintaining the integrity and effectiveness of such systems used for instance, in hydraulic test rigs, calibration, confirmation of hydraulic pump outputs, plus setting and adjustment of flow control valves. Maintaining consistent process conditions, however, can be challenging. Hydraulic systems rely on the precise movement of fluid to transmit power, and any deviation from the required flow rate can lead to performance issues, excessive wear, or system failure. For instance, process conditions
such as temperature fluctuations throughout the day can alter fluid viscosity and volumetric flow measurements, impacting flow measurement accuracy. Ideally hydraulic system designs should aim to minimise as many variables as possible within a reasonable cost. Once this foundation is established, equipment such as flow meters, pumps, and valves can be selected to effectively compensate for any parameter variations. Flowmeters are designed to measure the rate and/or volume of fluid flowing through a hydraulic system via a variety of outputs, from a simple mechanical display to full data logging, providing real-time data on the rate of fluid movement. This enables operators to monitor system health, detect leaks or blockages, and optimise performance. Accurate flow measurement is also crucial for maintaining consistent pressure and ensuring that actuators and other components receive the correct volume of fluid, which is vital for achieving the desired mechanical output.
Hydraulic fluids are typically viscous oils, petroleum or synthetic-based, utilised for their stability at operating temperature and lubricating properties, although water-based liquids (HFA, HFB), Water Glycol Fluids (HFC) and increasingly Biodegradable Hydraulic Fluids are also used within hydraulic systems.
October 2025 Instrumentation Monthly
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