Measuring systems for compressed air and gases

From the supply line of a process to the process itself, there are many places where leaks can form. Consumption measurement is important because there is an enormous potential for savings in the event of leakage, especially with compressed air (argon, nitrogen and oxygen are much more expensive). A sample calculation is given below to illustrate this:

A medium-sized production company is given.

Flow

In order to enable an accurate measurement of a flow rate, there must be a laminar flow, because this is the only way to reliably calibrate. Depending on factors such as the density, viscosity, pipe diameter and velocity of the air, either laminar or turbulent flow can occur.

Measure flow

Thermal mass flow
This thermal measurement method uses a sensor with two platinum resistors. R1 measures the gas temperature as a reference to R2, which is heated to a constant, previously determined temperature (e.g. 10° C above the value that R1 delivers).
The higher the power, around R2 at constant temperature hold, the higher the mass flow that flows through.
This process is ideal for dry and processed compressed air, technical gases and mixed gases.

Differential pressure principle
An integrated differential pressure sensor measures the dynamic pressure at the sensor tip. The dynamic pressure depends on the speed of the medium in the pipe. The flow rate can be determined by the pipe diameter.
The differential pressure method is used in hot and wet conditions. The sensor can be attached directly to the outlet of the compressor. It also offers fad measurement. This process is intended for top speeds of up to 600 Nm/s. Measurements of fast processes are possible up to a speed of 100 ms.