Tackling Flow Summation Challenges with the VEGAMET 862

Why flow measurement isn’t always straightforward
Accurately measuring flow at wastewater treatment works can be a tricky and expensive process – particularly when multiple streams need to be combined or subtracted to report true flow volumes.

Under the Environment Agency’s MCERTS scheme (specifically U_MON4), water companies are required to report precise flow data. This has traditionally meant large PLC setups, complex infrastructure, and costs of up to £35,000 per site – plus ongoing maintenance, technician training, and hardware upgrades. The VEGAMET 862 controller offers a practical, efficient alternative that delivers accurate flow summation without the burden of full-scale PLC systems.

One device, two inputs, zero fuss
The VEGAMET 862 accepts two flow signals and performs differential or totalised calculations internally. This removes the need for complex control systems, allowing existing infrastructure to remain in place – no new panels, cabling, or programming required.

At a Severn Trent Water treatment site, the controller was used to:

• Accept inlet and return flow measurements from two different flowmeters
• Calculate net flow (inlet minus return)
• Log data from both flowmeters for audit and reporting
• Output real-time values for visibility and control

It worked seamlessly with existing equipment, avoiding the need to replace or reconfigure existing flowmeters.

A simple fix for a common problem
In many cases, sites reuse treated effluent as washwater. When this is returned upstream of the inlet meter, it causes inflated flow readings and inaccurate reporting. Traditionally, correcting this meant reengineering the entire system.

Instead, the VEGAMET 862 offered a straightforward solution: perform the subtraction within a single unit, display the result clearly, and feed it straight into telemetry systems.

What difference does it make?
The site achieved accurate, consistent flow summation using a single compact controller. No major engineering work was required, and disruption was kept to a minimum. The system has continued to perform reliably, even in harsh wastewater conditions.

With increasing demand for reliable flow data and tighter requirements on environmental performance, simple solutions that work with existing systems are vital. The VEGAMET 862 supports:

• Improved operational clarity – real-time visual feedback and diagnostics
• Reduced site complexity – no need for extra PLCs or engineering changes
• Better long-term resilience – less hardware, less maintenance
• Stronger data confidence – accurate flow values that reflect actual conditions

By rethinking how flow summation is delivered, the VEGAMET 862 gives water companies a straightforward path to better measurement – one that’s cost-effective, reliable, and built for the realities of the industry.

Come speak to our team about our flow summation solutions at the Environmental Services & Solutions Expo this year from 17-18 September at the NEC, Birmingham! We will be at the WWEM area, on stand WW-P50. We will have on stand live demonstrations of our level, pressure, and flow measurement solutions, approved for use across drinking and wastewater applications.
Read more and register for your free visitor pass here.

Contact info.uk@vega.com for more information or call +44 1444 870055.

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