Step 6 for Compressed Air Analysis : Mapping out compressed air consumption with flowmeters

It is important to ask the right questions regarding consumption measurement in a compressed air system:

1. Is the compressed air system correctly sized among compressor capacity, distribution lines, and usage demands? 
2. What is the operating cost of the compressors? How much compressed air is generated per unit cost among different compressor?
3. What are the consumption peaks in the demand? Is the consumption justifiable with the production load? With such data, how do we plan and optimize appropriately for the load of compressors.
4. Determining offset flows and production lows (quantifying leaks in off-production times).
5. Consumption between different phases of production and users, what are the reasons behind the usage behavior?
6. Fluctuations in consumption reflects the health of the compressors and system. Are the reasons for the fluctuations and deteriorating performance over time correctly defined?

To answer these questions and more, it is important to size and map out the flow at optimized locations:

1. Measurement of wet compressed air after compressors.
2. Amount of air entering different buildings, phases of production.
3. Amount of air entering the ring main distribution system.
4. Amount of air used by individual machines.

The two types of flowmeters used to measure compressed air consumption are thermal mass flowmeters and differential pressure flowmeters:

Thermal mass flowmeters consists of 2 temperature resistors, R1, R2 and a heater. R1 measures the temperature of the gas, while R2 is heated to a constant delta temperature that will be cooled down by passing gas. The amount of heating power required to keep R2 at constant delta temperature is proportional to passing mass flow.

Differential Pressure Flowmeters consists of a integrated, precise differential pressure that measures dynamic pressure at the sensor tip, which is respective of gas velocity. With the pipe diameter known, the flow of compressed gas is easily determined. 

Comparisons between Thermal Mass Flowmeters and Differential Pressure Flowmeters, which to choose?

CS Instruments offers a wide variety of Thermal Mass Flowmeters (VA Series) and Differential Pressure Flowmeters (VD Series) for compressed flow measurement under different conditions. Accompanied with accessories like thickness meters, high-pressure protection, spot drilling collars and drilling jigs for ease of installation at site. 

CS Instruments Flow meter solutions