Case study · Precision pumps & injection systems

Generating a stable reference flow across a 1-to-5,500 range: A water meter calibration bench

Q: How can this calibration bench be adapted for corrosive or viscous fluids?

Adapting to different fluids is at the core of what we do. The modular pump architecture would remain the same. We would select materials compatible with your fluid (e.g., Hastelloy for acids, see our pump for sulfuric acid), and size the motorization for the viscosity. The design complies with the Pressure Equipment Directive (PED), ensuring safety.

Q: Is it possible to achieve higher flow rates or pressures with this type of flow generator?

Yes, the architecture is designed to be modular. For other ranges, we combine different pump bodies and motorizations. We have built precision injection systems that reach several thousand bar. The limit is a trade-off between the desired dynamic range, maximum pressure, and the total volume to be injected continuously.

Q: Can this system be integrated into an existing process loop for continuous flow control?

Yes, the equipment can be designed as an injection module for integration into a production line or a process pilot plant. The control system would then be adapted to communicate with your SCADA system and operate continuously, for example by using an alternating pump system to avoid any flow interruption during refilling.

Q: What is the flow rate measurement accuracy and how is it guaranteed?

Accuracy is a key design parameter that dictates the choice of technology and instrumentation. Our ISO 9001 certification governs this process.

For a manufacturer of utility metering equipment, IRIAN Mecatronics designed and built a custom water meter calibration bench. The equipment generates a metrology-grade reference flow with constant accuracy over a 1-to-5,500 range, at a stable, standardized temperature.

Client: Manufacturer of smart metering equipment for public utilities
Field: Fluid Metrology
Technique: Flow meter calibration

01 — The research question

Generating a stable and accurate reference flow over a very wide dynamic range

Generating a stable, known flow rate with high accuracy is a classic metrology challenge. The difficulty grows exponentially with the required dynamic range, as the technologies optimized for very low flows are fundamentally different from those needed for high flows.

This project's goal was to validate fiscal water meters over their entire operating range, from 1 L/h to 5,500 L/h, with a single test bench. A standard pump hits a dead end here: one sized for the maximum flow rate lacks accuracy and stability at very low speeds, while one designed for the finesse of low flows cannot deliver the required power.

How can we guarantee constant metrological accuracy over a 1-to-5,500 flow rate range, while also controlling the thermal stability of the test fluid?

02 — Our approach

Our approach: From physical hurdles to design principles

To meet this need, our engineering team analyzed the three interdependent physical challenges: generating flow over a wide range, controlling temperature, and compensating for deformation under pressure. Each design choice stems directly from these constraints.

Ensuring accuracy over a 1-to-5,500 dynamic range

To guarantee perfect linearity from a near-drip (1 L/h) to full flow (5,500 L/h), we ruled out a single-pump design. Our modular architecture uses specialized actuators for different flow sub-ranges. This gives the user a single bench for the entire test spectrum, without compromising on accuracy.
Controlling the fluid's thermal stability

The test protocols at +25°C (77°F) and +50°C (122°F) require rapid temperature changes. To counter the high thermal inertia of the pumps, we designed an active thermoregulation system using a heat exchanger. It heats and cools the circuit, cutting the stabilization time from 50°C to 25°C to under 10 minutes and maximizing the bench's productivity.
Compensating for circuit deformation under pressure

Pressurizing the system up to 25 bar (363 psi) causes the pump bodies to deform elastically, which skews the delivered volume. Rather than resorting to costly oversizing, we modeled this deformation. A real-time correction algorithm compensates for the physical effect, ensuring the accuracy of the injected volume regardless of the pressure.

03 — Beyond this project

Is your need similar? What would stay, what would change.

Pharmaceuticals / Biotechnology

For precisely dosing reagents into bioreactors, the dual-pump principle for dynamic range and the double-jacket thermal regulation would be retained. Materials (316L stainless steel, PEEK) and sanitary design (CIP/SIP) would be adapted to GMP requirements.

Aerospace / Automotive

To test fuel injectors or pumps at different rates, the modular architecture, thermal regulation, and pressure compensation would remain relevant. The fluids (kerosene) and safety standards (ATEX) would dictate specific materials and seals.

Geoscience / CO2 Capture

For the controlled injection of fluids (supercritical CO2) into rock samples, the dual-pump principle for dynamic range and high-pressure deformation compensation are directly transposable. The design would evolve for much higher pressures and temperatures, with materials like Hastelloy.

04 — Specifications

The values for this project. Every system is custom-built, so they adapt to your requirements.

Show specifications · 1 to 5,500 L/h · 25 bar (363 psi) · +25°C (77°F) and +50°C (122°F)

Technical specifications — Generating a stable reference flow across a 1-to-5,500 range: A water meter calibration bench
Flow rate range	1 to 5,500 L/h
Maximum operating pressure	25 bar (363 psi)
Test temperature setpoints	+25°C (77°F) and +50°C (122°F)
Cooling time (50°C to 25°C)	< 10 minutes

IRIAN Mecatronics designs and builds custom high-pressure, high-temperature equipment for research laboratories, technical centres and industry.

About the company

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05 — FAQ

Frequently asked questions

How can this calibration bench be adapted for corrosive or viscous fluids?

Adapting to different fluids is at the core of what we do. The modular pump architecture would remain the same. We would select materials compatible with your fluid (e.g., Hastelloy for acids, see our pump for sulfuric acid), and size the motorization for the viscosity. The design complies with the Pressure Equipment Directive (PED), ensuring safety.

Is it possible to achieve higher flow rates or pressures with this type of flow generator?

Yes, the architecture is designed to be modular. For other ranges, we combine different pump bodies and motorizations. We have built precision injection systems that reach several thousand bar. The limit is a trade-off between the desired dynamic range, maximum pressure, and the total volume to be injected continuously.

Can this system be integrated into an existing process loop for continuous flow control?

Yes, the equipment can be designed as an injection module for integration into a production line or a process pilot plant. The control system would then be adapted to communicate with your SCADA system and operate continuously, for example by using an alternating pump system to avoid any flow interruption during refilling.

What is the flow rate measurement accuracy and how is it guaranteed?

Accuracy is a key design parameter that dictates the choice of technology and instrumentation. Our ISO 9001 certification governs this process.

Does your current equipment lack the accuracy or dynamic range to qualify your components?

Describe your flow, pressure, and temperature constraints. Our engineering team will analyze your project's feasibility and get back to you with a design proposal.

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