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Gas Flow Controllers: Automated Factory Gas Blending and Allocation Blocks
Quick Answer
For automated factory gas blending and allocation blocks, gas flow controllers based on mass flow measurement beat volumetric metering because gas density shifts with pressure and temperature. Silver Automation Instruments supplies thermal mass and Coriolis mass flow controllers from DN15 to DN50 with 4-20 mA HART and optional ATEX Zone 1 certification. Send your gas type, pressure in bar, temperature in °C, pipe size DN, and flow range for a specific quote.
Where Blending Blocks Go Wrong
Most gas blending skids fail at low flow. A nitrogen purge line may run at 0.5 kg/h with line pressure at 2 bar. Volumetric flow meters misread this because density changes with temperature. Thermal mass flow controllers read mass directly. We have seen a paint manufacturer in Vietnam replace three turbine meters after batch ratios drifted by 4 percent.
In practice, allocation blocks need stable split ratios. A biogas blending station in Indonesia blends landfill gas with LPG before feeding a boiler. The gas mix changes daily. The flow controller must hold a setpoint within ±0.5 percent of reading. Standard rotameters cannot do that.
Flow Controller Selection for Blending Skids
For clean gas blending we normally quote the Silver Instruments TMF-15A thermal mass flow controller. It covers 0 to 50 Nm3/h on a DN15 line, works with 4-20 mA HART, and holds ±0.5 percent of reading. For allocation blocks with changing gas composition, the CMF-25 Coriolis mass flow controller is better. It reads true mass flow independent of gas type.
Here is the thing. A flow controller is not a flow totalizer. Blending skids need a controller with valve response in under one second. The TMF-15A responds in 0.8 seconds on DN15 lines. Because the control valve is integrated, wiring is simpler. You only run power and a 4-20 mA HART loop.
Many Southeast Asia and Middle East orders request ATEX Zone 1. The TMF-15A can be supplied with Ex db IIC T4 enclosure and stainless steel wetted parts. Specify this before pricing because it changes lead time by 4 working
Installation Notes on DN15 and Small Lines
Use a straight run of 10 DN upstream and 5 DN downstream for thermal mass controllers in blending skids. Mount the controller before the blending tee, not after. If you place it after the tee, gas mixing turbulence creates noise. Most engineers skip this part and then see unstable output.
For allocation blocks, install a separate flow controller on each branch. Do not use one meter and assume equal split. We saw a natural gas allocation block in Nigeria where one branch was shorter by 6 meters. The flow split was 58/42, not 50/50.
Price and Lead Time Reality
Budget for a DN15 thermal mass gas flow controller from Silver Instruments is around 1,200 to 2,400 USD depending on ATEX and valve type. Lead time is typically 8 to 12 working days from our Nanjing workshop. Coriolis mass flow controllers for allocation blocks start around 4,500 USD and ship in 12 to 15 working days.
FAQ
What gas types can the TMF-15A handle?
The thermal mass flow controller works with clean gases like nitrogen, argon, oxygen, biogas, natural gas, and carbon dioxide. For dirty or wet gas, use the Coriolis option.
Do I need a separate valve for flow control?
No. The TMF-15A includes an integrated control valve. You can set the flow setpoint through 4-20 mA HART or Modbus RTU.
Can these controllers work in ATEX Zone 1?
Yes. Silver Instruments can supply ATEX Zone 1 versions with Ex db IIC T4 enclosure. Lead time increases by about 4 working days.
What is the minimum flow rate you can control on a DN15 line?
Typical minimum is 0.1 Nm3/h for thermal mass control and 0.05 kg/h for Coriolis control. Tell us your gas composition and pressure so we can confirm the range.
How do I get a price for a gas blending allocation block?
Send us the number of branches, gas type, pressure, temperature, pipe size and flow range. We reply with budget pricing and a GA drawing within one working day. Tel: +86-25-68650347. WhatsApp: +86-25-52155837. WeChat: +86 15365082610.
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