Henan Zhongce Sensing High-Pressure Electromagnetic Flowmeter: A flow measurement solution designed for high-pressure operating conditions in the petrochemical industry.

In the petrochemical industry, fluid pressures within pipelines often far exceed those encountered in typical industrial settings. For instance, water‑injection systems in oilfields can operate at pressures of several tens of megapascals, while coal‑water slurry transport in gasification units also falls within the high‑pressure range. Under such operating conditions, conventional electromagnetic flowmeters struggle to meet the stringent requirements for sealing and structural integrity. In response to the high‑pressure measurement needs of the petrochemical sector, Henan Zhongce Sensor Technology Co., Ltd. has introduced a series of high‑pressure electromagnetic flowmeters capable of withstanding up to 42 MPa, providing a specialized solution for flow monitoring in high‑pressure pipelines.

Product Positioning and Technical Specifications

The Henan Zhongce Sensing high-pressure electromagnetic flowmeter is a velocity-type flow meter specifically designed for measuring conductive liquids. It offers nominal pressures spanning multiple classes—6.3 MPa, 10 MPa, 16 MPa, 25 MPa, 32 MPa, and 42 MPa—with the highest rating reaching 42 MPa. The product’s nominal pipe sizes typically range from DN15 to DN200, and it can be customized to match on-site pipeline specifications.

This product series is primarily designed for specific application scenarios in the petrochemical industry, including high-pressure water‑injection metering in oilfields, drilling‑fluid flow monitoring, cement‑slurry injection measurement, coal‑to‑liquids slurry transport, and metering of acidic, alkaline, and saline solutions in high‑pressure pipelines for chemical feedstocks. These applications share common characteristics: high pipeline pressures, complex fluid compositions, and stringent requirements for instrument pressure resistance and reliability.

Working principle

High‑pressure electromagnetic flowmeters operate on the same principle as conventional electromagnetic flowmeters, both relying on Faraday’s law of electromagnetic induction. When the excitation coil inside the sensor is energized, it generates a stable magnetic field. As a conductive liquid flows through the measuring tube, it cuts across the magnetic field lines, inducing an electromotive force whose magnitude is directly proportional to the fluid velocity. The induced signal is picked up by electrodes and transmitted to the converter, which amplifies, filters, and digitizes it. The result is the instantaneous flow rate and the cumulative total, which are then output to the control system via interfaces such as 4–20 mA, pulse, or RS‑485.

The core distinction between high-pressure products and conventional ones lies in their structural design. When subjected to pipeline pressures several times higher than standard, the wall thickness of the measuring tube must be precisely calculated, the flange‑to‑flange mating surfaces require special reinforcement, and electrode sealing must employ more reliable sintering or inlay techniques to ensure long‑term sealing integrity even at pressures as high as 42 MPa.

Main Technical Features

Pressure resistance up to 42 MPa. Henan Zhongce Sensing’s high-pressure electromagnetic flowmeters can operate at a maximum pressure of 42 MPa, meeting the measurement requirements of most high-pressure pipelines in the petrochemical industry. This pressure rating complies with the industry‑wide standard for high‑pressure flowmeters and offers robust engineering suitability for applications such as oilfield water injection and drilling fluid transport.

Optimized flow channel structure. The measuring tube contains no flow‑obstructing or moving parts, resulting in zero additional pressure loss. This is especially critical for high‑pressure systems—since high‑pressure pumping inherently consumes significant energy, any extra pressure drop would further increase pump load and operating costs. Moreover, the absence of moving parts reduces routine maintenance requirements and minimizes the risk of failures caused by mechanical wear.

Flexible configuration of the liner and electrode materials. Depending on the medium’s composition, users can select appropriate lining and electrode materials. For linings, options include PTFE (polytetrafluoroethylene), F46, polyurethane, PFA, and others; for electrodes, materials range from 316L stainless steel to Hastelloy B, Hastelloy C, titanium, tantalum, and more. For instance, when the medium contains solid particles such as sand or mineral slurry, a wear‑resistant polyurethane lining is recommended; if the medium is highly corrosive, an F46 or PFA lining should be paired with corrosion‑resistant electrodes. The medium’s electrical conductivity must be ≥5 μS/cm, a requirement typically met by common acid, alkali, and saline solutions.

Multifunctional support for the smart converter. The high‑pressure electromagnetic flowmeter from Henan Zhongce Sensor is equipped with an intelligent converter that employs an embedded microprocessor and digital excitation technology, offering features such as self‑diagnostic alarm output, empty‑pipe detection, and upper/lower flow limit alarms. The converter supports both integrated and split‑type installation configurations. In the split‑type configuration, the converter is mounted separately from the sensor: the sensor is installed on pipelines subjected to high temperatures or significant vibration, while the converter is placed in a more favorable environment, thereby extending the service life of electronic components and reducing maintenance costs.

Connection method and installation adaptability. Connection options for high-pressure models include flanged connections and nipple‑type connections. Flanged connections are suitable for standard high-pressure pipeline splicing, while nipple‑type (nipple) connections are more commonly used in oilfield operations, enabling quick on‑site installation and removal—particularly well‑suited for drilling platforms and other settings where frequent relocation or changes in measurement points are required. Sensor protection ratings can reach IP65, IP67, or IP68, making them ideal for outdoor or humid environments. For petrochemical facilities with explosion hazards, an explosion‑proof enclosure (Ex d) is also available to meet the installation requirements of hazardous areas.

Typical applications in the petrochemical industry

Henan Zhongce Sensing’s high-pressure electromagnetic flowmeters are applicable in a variety of specific scenarios within the petrochemical industry.

High-pressure water injection metering in oilfields. During oil production, maintaining formation pressure through water injection is a widely used method for enhancing oil recovery. The operating pressure of water‑injection systems typically exceeds 10 MPa, and in some deep‑well injection projects can reach as high as 42 MPa. High‑pressure electromagnetic flowmeters are installed on the injection pipelines to monitor injection flow rates in real time, providing data support for oilfield operators to optimize injection strategies and allocate water resources effectively.

Drilling fluid flow monitoring. During drilling operations, drilling fluid must be pumped from the surface to the bottom of the wellbore under high pressure. Electromagnetic flowmeters are installed on the drilling‑fluid delivery line to monitor the inflow rate in real time, enabling engineers to assess downhole conditions. High‑pressure‑rated models offer two key advantages in this application: robust resistance to high pressure and strong immunity to electromagnetic interference. They are unaffected by fluid density, viscosity, temperature, or particulate matter, making them well suited for drilling fluids containing sand, silt, and other contaminants.

Coal chemical water-slurry metering. The coal-water slurry gasification unit operates at relatively high pressures, and its process fluid is a solid–liquid two-phase flow (a slurry composed of coal powder and water), placing stringent demands on the flowmeter’s pressure resistance and wear resistance. In such systems, high-pressure electromagnetic flowmeters serve as critical measurement components, regulating the slurry flow rate into the gasifier and directly impacting the gasifier’s operational efficiency and energy consumption.

Chemical raw material conveying pipeline. In refining and petrochemical processes, large volumes of acidic, alkaline, and saline solutions must be conveyed through high-pressure pipelines. Electromagnetic flowmeters, with no obstructive components inside the measuring tube, do not impose additional resistance to fluid flow, and—when equipped with appropriate linings and electrodes—can withstand the corrosive effects of highly aggressive media, making them a highly suitable choice for such applications.

Points to Consider When Selecting a Model

Selection of pressure rating. Users should select the flow meter’s nominal pressure rating based on the pipeline system’s maximum operating pressure. As a general rule, choose a product one pressure class higher than the system’s maximum pressure to provide an adequate safety margin. For example, if the system’s operating pressure is 20 MPa, a 25 MPa‑rated meter is recommended; if the system’s operating pressure reaches 35 MPa, a 42 MPa‑rated meter is advised.

Confirmation of the dielectric conductivity. Electromagnetic flowmeters are suitable only for conductive liquids, with a minimum medium conductivity of 5 μS/cm. They are not applicable to non-conductive or low-conductivity media such as pure water, deionized water, oils, and organic solvents.

Matching of the liner material with the electrode material. Select the lining and electrode materials based on the medium’s temperature, corrosivity, and whether it contains solid particles. In general, F46 and PFA offer excellent corrosion resistance and thermal stability; polyurethane linings exhibit superior wear resistance and are well suited for slurry‑type media; while Hastelloy and tantalum electrodes demonstrate strong resistance in highly acidic or highly alkaline environments.

Installation requirements. The measurement accuracy of electromagnetic flowmeters is influenced by the velocity profile downstream. To obtain more accurate results, it is recommended to provide a straight pipe section of at least five times the pipe diameter upstream and three times the pipe diameter downstream, ensuring that the fluid velocity profile is sufficiently developed and stable. Additionally, avoid strong electromagnetic interference sources and ensure that the sensor housing is properly grounded.

Maintenance and Reliability

The high‑pressure electromagnetic flowmeter from Henan Zhongce Sensing is designed with a focus on long service life and minimal maintenance. Routine inspections primarily address the following aspects: regularly check the electrode area for signs of leakage—assessed by monitoring whether the junction box interior has become damp; examine the liner for blisters or cracks caused by erosion or chemical corrosion; and verify that the grounding ring is properly grounded, as media in high‑pressure pipelines often carry stray currents, and reliable grounding helps ensure measurement accuracy. During periods of inactivity, keep the measuring tube fully filled with liquid or perform appropriate cleaning to prevent the liner from drying out and cracking.

Summary. The Henan Zhongce Sensing High‑Pressure Electromagnetic Flowmeter is a flow‑measurement instrument designed for high‑pressure applications in the petrochemical industry, with a maximum operating pressure of up to 42 MPa. From the design of the measuring tube structure and flange‑connection strength to electrode sealing processes and liner material selection, the product prioritizes safety and reliability under high‑pressure conditions. It provides an effective solution for measuring the flow of conductive liquids at elevated pressures in fields such as oilfield water injection, drilling‑fluid monitoring, coal‑water slurry metering, and chemical feedstock transportation. When selecting a model, users should consider pipeline operating pressure, fluid characteristics, and installation constraints to choose an appropriate configuration, and ensure proper installation and maintenance in accordance with relevant standards to guarantee stable measurement data and extend equipment service life.