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Compressed Air Flow Measurement – Increasing Efficiency with Precision

Why is Compressed Air Flow Measurement Important?

Compressed air is one of the most expensive energy sources in industry. Up to 30% of generated compressed air is lost due to leaks – representing a huge savings potential! Precise compressed air flow measurement helps to collect consumption data, identify inefficiencies, and reduce costs.

Basics of Compressed Air Flow Measurement

Flow measurement is used to determine the volume flow (m³/h, l/min) or mass flow (kg/h) of compressed air. This data is essential for:

  • Analyzing the actual compressed air consumption of machines,
  • Detecting leaks in the compressed air pipeline at an early stage,
  • Avoiding peak loads and optimizing the efficiency of compressed air supply.

Measurement Methods for Compressed Air Flow

1. Calorimetric Flow Measurement

The calorimetric measurement method is particularly precise and low-maintenance. A sensor is heated, and the cooling effect of the flowing medium provides the measurement value.

2. Differential Pressure Measurement

This method measures the pressure difference before and after a constriction in the pipe. It is suitable for large flow rates but causes a certain pressure loss.

3. Ultrasonic Measurement

Ultrasonic sensors measure the travel time of sound waves through the medium. This method is non-contact and particularly suitable for large pipe diameters.

Advantages of Precise Compressed Air Measurement

  • Energy savings: Detecting leaks and optimizing control
  • Cost reduction: Accurate consumption data prevent oversized compressors
  • Early fault detection: Anomalies in the air supply become visible
  • Industry 4.0 & Monitoring: Integration with higher-level systems via Modbus, M-Bus, or Ethernet

Which flow meter is the right one?

DeviceFeaturesSpecial Advantages
VA 525Compact, calorimetric measurement methodIntegrated flow straightener, no inlet sections required
METPOINT® BDLMobile data measurementIdeal for energy management & leak detection
Inline Flow Sensor VA 520Measurement also for different gasesHigh flexibility, easy retrofit, very precise, low maintenance

Integration into Existing Compressed Air Systems

  • Positioning: Sensors should be installed in straight pipe sections without turbulence.
  • Inlet sections: Depending on the measurement method, certain pipe lengths must be kept free before and after the sensor.
  • Digital connectivity: Modern sensors offer Modbus RTU, Ethernet, or M-Bus for seamless integration into energy management systems.

Why Compressed Air Flow Measurement is Worth It

  • Reducing energy costs through optimized control
  • Sustainability through more efficient use of compressed air
  • Increased system availability through early fault detection

If you want to make your compressed air systems more efficient, take a look at our high-quality flow meters! We will be happy to advise you on which flow meter is best for your compressed air or gas measurement needs.


We recommend the following flow meters:

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02-663 NTron Oxygen sensor
02-663 NTron Oxygen sensor, SenzTx-102 (0-96%) O2 03-909 Inmatec oxygen sensor alternatively, SenzTx-102 (0-96%) O2 The SenzTx replacement ppm o2 sensor is a compact and robust O2 transmitter that utilises zirconia or electrochemical technology to give a reliable measurement of oxygen concentration. ApplicationsGas generation (oxygen / nitrogen)Additive manufacturingGlove box purge and leak detectionIndustrial gas applications FeaturesZirconia or electrochemical sensor technology optionsMeasurement range: 0 to 10ppm up to 0 to 100% O2Analogue output: 4 to 20mAModbus 48524VDC power supplyM12 electrical connectionProcess connection: KF40 Flange or Flowthrough baseCombined Sensor & Electronics allows for ease of integration.Fast response from ambient air to low PPM oxygen measurement Senz-TX oxygen sensors for measuring oxygen levels in various applications Using Senz-TX oxygen sensors can be considered part of a PSA Gas generator. These sensors are specifically designed to measure oxygen levels in various applications, including compressed air systems. By incorporating Senz-TX sensors into a monitoring system, operators can track and analyze oxygen concentrations in the oxygen PSA generators to ensure that it meets the required quality standards. When integrated into a oxygen generator, Senz-TX sensors can provide real-time data on oxygen levels, allowing operators to detect any deviations from the desired concentration. This information can help identify potential issues with the compressed air system, such as leaks or contamination, and take corrective actions promptly. In addition to monitoring oxygen levels, a comprehensive air separation monitoring system may also include other sensors and devices to measure parameters like pressure, temperature and humidity levels. By combining multiple sensors and monitoring tools, operators can gain a more complete understanding of the overall quality and performance of their compressed air system. Overall, using Senz-TX oxygen sensors as part of an oxygen monitoring system can help ensure that the oxygen PSA generator meets the necessary quality standards and operates efficiently and reliably.

Net €1,120.00 €1,332.80* €1,666.00* (20% saved)
METPOINT®️ BDL p. with DPM Set
METPOINT®️ BDL p. with DPM Set - mobile data logger Mobile data recording METPOINT® BDL portable set › Mobile data logger BDL portable › DPM SD23 dew point transmitter with dry protection sleeve › MK-Basic-PN16 measuring chamber with quick-release coupling › Power supply unit  › LiCl 11,3% RH control and calibration kit  › 5m connecting cable with quick-release coupling for SD23   › Sturdy transport case METPOINT®️ BDL portable One can see quality – one just needs to record it The portable METPOINT BDL data logger allows for the quick and easy measurement and evaluation of your compressed air quality – at any point in your system. This universal hand-head device with integrated data logger has been specially designed for the recording of key parameters, such as consumption and flow rate, pressure, temperature, residual humidity and pressure dew point. All process data is converted into user-friendly statistics and charts. Up to 100 million measurements together with the time and location of measurement can be stored and called up in the form of characteristics in colours. The universal sensor inputs are compatible with all conventional industrial transducers. The device comes with a 3.5" touch screen and intuitive user interface. Other great features of the compact METPOINT® BDL portable are its integrated data logger, the colour display of characteristics for analysis and various interpretation functions. All measurements can be transferred with an USB memory stick to a PC for further evaluation by means of the METPOINT® READER SW201 evaluation software. You can monitor the performance of your system in real time and take action when needed. With the METPOINT® BDL portable, you have the data you need at your fingertips. ISO 8573 oil class information with dew point sensor METPOINT BDL p. with DPM set The Metpoint BDL p. dew point sensor with DPM set is a high-performance device designed to accurately measure the dew point of compressed air. This sensor is capable of providing valuable information regarding the moisture content of the compressed air, which is crucial for maintaining the quality and performance of the compressed air system. In addition to measuring the dew point of compressed air, the Metpoint BDL P sensor with DPM set can also be used to determine the oil content in the compressed air. By analyzing the moisture and oil content of the compressed air, users can obtain important data that can be used to classify the quality of the compressed air according to ISO 8573 standards. ISO 8573 is an international standard that defines the purity classes of compressed air based on the levels of contaminants present, including particles, water, and oil. By using the dew point sensor with DPM set in conjunction with other monitoring devices, users can accurately assess the quality of the compressed air and determine its ISO 8573 oil class classification. Overall, the Metpoint BDL P dew point sensor with DPM set provides valuable information regarding the moisture and oil content of compressed air, enabling users to maintain high-quality compressed air systems that meet ISO 8573 standards for purity and performance.

Net €3,216.00 €3,827.04*
VA 525 - Compact inline flow sensor for air and nitrogen
VA 525 - Compact inline flow sensor for air and nitrogen No inlet section necessary – integrated flow straightener – optional pressure sensor The innovative VA 525 combines modern digital interfaces for connection to an energy monitoring system with a small, compact design. The VA 525 is always used when many machines (compressed air consumers) have to be integrated into an energy monitoring network. Reduce your energy costs and increase your sustainability with the VA 525 compact sensor. Monitor the consumption of individual machines and analyze your leakage flows with just one measuring device. Flow measuring ranges VA 525 (max version 185 m/s) for compressed air (ISO 1217: 1000 mbar, 20 °C) Measuring section Thread Measuring range full scales L B H1 H A     m3/h (cfm) mm mm mm mm mm DN 8 G 1/4" 105 I/min 3.6 135 55 50 109.1 15 DN 15 G 1/2" 90 m3/h 50 135 55 50 109.1 20 DN 20 G 3/4" 170 m3/h 100 135 55 50 109.1 20 DN 25 G 1" 290 m3/h 170 135 55 50 109.1 25 DN 32 G 1 1/4" 530 m3/h 310 135 80 80 139.1 25 DN 40 G 1 1/2" 730 m3/h 430 135 80 80 139.1 25 DN 50 G 2" 1195 m3/h 700 135 80 80 139.1 30 Advantages of VA 525:Compact, small design - for use in machines, behind maintenance unit on the end user Optionally with conventional analogueue signals (4…20 mA and pulse) or digital interfaces such as Modbus-RTU, Ethernet (also PoE), M-Bus All interfaces are freely programmable via the display

From Net €895.00 €911.91*
Inline Flow meter VA 520 - thread
Inline Flow meter VA 520 - thread Available items Inline Flow meter VA 520 - thread measuring section: Product Description Order No. VA 520 flow meter with 1/2" measuring section    0695 1521 VA 520 flow meter with 3/4" measuring section    0695 1522 VA 520 flow meter with 1" measuring section    0695 1523 VA 520 flow meter with 1 1/2" measuring section    0695 1524 VA 520 flow meter with 2" measuring section   0695 1525 1/2" 3/4" 1" 1 1/2" 2     l/min (cfm) l/min (cfm) l/min (cfm) l/min (cfm) l/min (cfm) Reference conditions DIN 1945 / ISO 1217: 20 °C, 1000 mbar Air Low-Speed (50 m/s) 20 (14) 45 (25) 75 (45) 195 (115) 320 (190) Standard (92,7 m/s) 45 (25) 85 (50) 145 (85) 365 (215) 600 (350) Max (185 m/s) 90 (50) 175 (100) 290 (170) 730 (430) 1195 (700) High -Speed (224 m/s) 110 (60) 215 (125) 355 (210) 885 (520) 1450 (850) Setting to DIN 1343: 0 °C, 1013.25 mbar Nitrogen (N2) Low-Speed (50 m/s) 20 (13) 40 (25) 70 (40) 180 (105) 295 (175) Standard (92,7 m/s) 40 (20) 80 (45) 135 (75) 335 (195) 550 (320) Max (185 m/s) 80 (45) 160 (95) 270 (155) 670 (395) 1100 (645) High-Speed (224 m/s) 100 (55) 195 (115) 325 (190) 815 (475) 1330 (780) Setting to DIN 1343: 0 °C, 1013.25 mbar Oxygen (O2) Low-Speed (50 m/s) 20 (13) 45 (25) 75 (40) 185 (115) 305 (180) Standard (92,7 m/s) 40 (25) 80 (45) 140 (80) 345 (205) 570 (335) Max (185 m/s) 85 (50) 165 (95) 280 (165) 695 (410) 1140 (670) High-Speed (224 m/s) 105 (60) 205 (120) 340 (200) 845 (495) 1380 (810) Advantages of the VA 520 flow meter: Measurement of mass flow rate, output of standard volume flow rate High accuracy for both small and large flows Pressure and temperature compensated by the thermal mass flow principle Easy installation and removal of the sensor, the integrated measuring section can remain in the line for cleaning or recalibration of the sensor and can simply be closed with a sealing cap No moving parts, therefore low maintenance Vanishingly low pressure loss due to vanishingly low blockage of the diameter Can be used for compressed air and non-corrosive gases such as nitrogen, oxygen, argon, helium, etc. Flow measuring ranges VA 520 (max version 185 m/s) for compressed air (ISO 1217: 1000 mbar, 20°C) Connection thread Outer pipe Inner pipe L L1 H H1 A   mm mm mm mm mm mm mm R 1/2" 21.3 16.1 300 210 176.4 165.7 20 R 3/4" 26.9 21.7 475 275 179.2 165.7 20 R 1" 33.7 27.3 475* 275 182.6 165.7 25 R 1 1/2" 48.3 41.9 475* 275 186.9 165.7 25 R 2" 60.3 53.1 475* 275 195.9 165.7 30 * Attention: shortened inlet section. Please observe the recommended minimum inlet section (length = 15 x inner diameter) on site! How inline flow meter VA 520 - thread can effect on ISO air quality chart? The ISO air quality chart provides guidelines for the maximum allowable levels of contaminants in compressed air systems based on the ISO 8573 standard. The ISO 8573 standard specifies purity classes for different contaminants such as particles, water, and oil in compressed air systems. When it comes to an inline flow meter like the VA 520 with a thread connection, the thread type and size can have an impact on the air quality in a compressed air system. The thread connection of the flow meter can potentially introduce contaminants into the system if not properly sealed or if the thread material is not compatible with the air quality requirements. It is important to ensure that the thread connection of the flow meter is properly sealed and does not introduce contaminants into the system. Additionally, the material of the thread should be compatible with the air quality requirements to prevent any contamination issues. When selecting an inline flow meter like the VA 520 for a compressed air system, it is essential to consider the thread connection type, size, and material to ensure that it does not negatively impact the air quality according to the ISO 8573 standard. It is recommended to consult the manufacturer's specifications and guidelines to ensure that the flow meter meets the air quality requirements of the system.

From Net €1,026.00 €1,220.94*
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