Life Cycle Analysis of Thermal Gas Mass Flowmeters

Thermal gas mass flowmeters are widely used in fields such as environmental protection, chemical engineering, and energy due to their advantages of directly measuring gas mass flow, having no moving parts, and having a fast response. However, the lifespan of their core components (such as sensors and heating elements) directly affects the long-term stability of the equipment. This article will analyze the key factors affecting their lifespan and provide practical suggestions for extending their service life.

1. Key Factors Affecting the Lifespan of Thermal Flowmeters

  (1) Sensor Aging

  Long-term high-temperature operation: Thermal flowmeters rely on temperature differences to measure flow. If they are exposed to high temperatures (>200°C) for a long time, the sensors are prone to oxidation or drift, resulting in reduced accuracy.

Corrosive gases: Gases containing sulfur, chlorine, etc., which are corrosive, can erode the sensor coating, shortening its lifespan.

  (2) Particulates and Contamination

  Dust or oil mist: Dust or oil mist accumulates on the sensor surface, affecting heat dissipation and thermal conduction, leading to measurement errors or component overheating and damage.

Coking or carbon deposition: Some process gases (such as combustion exhaust) may form deposits on the sensor surface, reducing sensitivity. 

  (3) Power Supply and Signal Stability

  Voltage Fluctuation: Frequent power fluctuations may damage the heating circuit or signal processing module.

Electromagnetic Interference (EMI): A strong electromagnetic environment may cause signal distortion and affect long-term stability.

2. How to extend the service life of the thermal flowmeter?

  (1) Rational Selection and Installation

  Choose corrosion-resistant materials: such as 316L stainless steel or sensors with special coatings, suitable for corrosive gases.

Pre-filtering: If the gas contains dust or droplets, add a filter to reduce pollution.

Avoid extreme temperatures: In high-temperature working conditions, choose high-temperature models with heat sinks or cooling devices.

(2) Optimize Operating Environment

Control gas flow rate: Avoid operating beyond the range to prevent sensor overload.

Reduce vibration: Use anti-vibration brackets during installation to avoid mechanical shock causing internal components to loosen.

(3) Regular Maintenance

Clean the sensor: Use isopropyl alcohol or compressed air to clean the surface of the probe when the machine is shut down.

Calibrate and test: Conduct zero point and range calibration every 6-12 months to ensure measurement accuracy.

3. When is a flowmeter replacement necessary?

Measurement drift cannot be corrected: Even after calibration, there is still a large error.

Heating element failure: The sensor cannot heat normally or respond slowly.

Physical damage: Such as probe fracture, circuit burnout, or seal failure. 

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