The Installation of Pressure Sensors on Air Compression Units

Pressure measurement is an integral component of the monitoring method that measures how economically an air compressor is running at all times.

The increasing energy prices have resulted in each unit within a factory always running at an optimal performance level, and for air compressors that means increasing or decreasing the compressor load to meet the changing requirement for compressed air throughout the factory lines.

For this purpose it is becoming more and more common to establish “air management” systems, which monitor the performance indicators and the different stages of the various air compressors which are connected to the compressed-air supply grid. through these air management systems, each compressor runs at the right power level at exactly the required time. To do this efficiently, pressure sensors are needed to monitor the output pressure of each compression stage, and with that can come many difficulties.

Air compressors are inclined to high levels of vibration, which means that a pressure sensor installed directly onto the body (housing) of a compressor is subjected to correspondingly high levels of vibration. This can often lead to the failure of many pressure sensors installed in such a way, unless they are pre-designed with such demanding working environments in mind.

Another major issue faced by pressure sensors installed on air compressors is the elevated ambient temperature – the compressor's moving parts and their very tight clearances lead to increased temperatures within the housing, which can result in temperature errors that present themselves on the output of a pressure sensor and lead to inaccurate power calculations.

One solution that compressor designers use to overcome these issues is installing pressure sensors remotely on a side panel next to the main housing of the compressor. Not only does this reduce exposure to both vibration and high ambient temperatures, it also defends the pressure sensors from the harmful effects of these conditions. Having a compact pressure sensor with a dual pressure thread (an external thread to fasten the sensor onto the side panel, and an internal thread to connect the air hose) is a helpful tool when designing such a solution. There are many solutions to such problems that TC Fluid can accommodate for. To find out how we can help, or if you would like any more information then please get in contact with us.

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