Source-Network-Load Framework of Gas Supply Systems and Pressure Monitoring Requirements

In modern gas infrastructure, the supply system forms a highly coordinated source-network-load architecture, where the gas source acts as the energy inlet, the transmission and distribution network handles transport and regulation, and the user end completes final consumption. This framework requires precise full-process pressure sensing to ensure system stability, prevent overpressure or underpressure risks, and optimize resource allocation. As a key B2B component, Nexisense pressure sensors support continuous monitoring from high-pressure sources to low-pressure terminals through embedded deployment, assisting integrators in building reliable energy management systems.

The gas source stage typically involves natural gas wellheads or LNG regasification stations. Gas in high-pressure conditions (typically 0.2–0.5 MPa) must be regulated through storage facilities for peak-shaving. Here, pressure sensors act as sentinels, providing real-time data feedback to control systems, enabling automatic pressure regulation and triggering safety valves. Upon entering the transmission and distribution network, system complexity increases, with high-pressure, sub-high-pressure, medium-pressure, and low-pressure pipelines interconnected. Pressure regulating stations at each level serve as hubs to gradually reduce pressure to safe levels. Sensors monitor pressure differentials, assist in flow calculation, and integrate into SCADA platforms to support remote dispatching.

Although pressure is lower at the user end, accuracy requirements are higher, especially in industrial applications. Sensors must be compatible with metering devices and correct temperature-induced errors to ensure optimized combustion efficiency. Overall, this source-network-load framework relies on distributed deployment of pressure sensors to form a closed-loop control network, meeting engineering project demands for reliability and scalability.

Application Scenarios of Pressure Sensors in Three Major Gas Supply Stages

Nexisense pressure sensors provide modular solutions for key nodes in gas supply systems, suitable for high-pressure gas sources, urban transmission networks, and terminal metering, ensuring seamless integration and efficient operation.

Gas Source End: High-Pressure Regulation and Safety Warning

At gas source inlets such as storage tanks or fueling stations, sensors are deployed at inlet pipelines and tank interfaces to monitor absolute pressure (abs) and gauge pressure (gauge), covering ranges from 0–10 MPa. A typical application is real-time pressure regulation monitoring: sensors output 4–20 mA analog signals or RS-485 digital interfaces, linked with PLC controllers to maintain inlet pressure within design thresholds and prevent pipeline overload.

For example, in an LNG regasification project, Nexisense sensors were integrated into storage facilities, combining differential pressure measurement to detect tank liquid level changes. When abnormal pressure occurs (such as overpressure caused by thermal expansion), sensors trigger emergency relief valves and activate alarm systems to prevent accident escalation. The solution is compatible with the Modbus protocol and supports IoT vendors in extending to cloud monitoring, enhancing overall project safety.

Transmission and Distribution Network: Pressure Gradient Monitoring and Leak Detection

The transmission and distribution system is the most densely deployed area for pressure sensors. Sensors are distributed at regulating stations, transfer stations, and pipeline nodes, measuring differential pressure to calculate flow (based on the Bernoulli equation). Nexisense products support high precision (±0.1% FS) measurement, suitable for medium-pressure networks (0.1–0.4 MPa). By monitoring pressure drop gradients, friction losses or leakage points can be identified.

In smart pipeline projects, sensor data is fed into SCADA systems, using algorithms to optimize valve opening and achieve dynamic load balancing. For example, an engineering company adopted Nexisense sensors in an urban gas upgrade project, integrating them into a wireless sensor network (WSN) to detect micro-pressure variations (as low as 0.01 kPa) and transmit data via LoRaWAN protocol. This case demonstrates system compatibility: sensors support multiple power options (24V DC or battery supply), facilitating deployment at remote sites and reducing maintenance costs.

Leak detection is another core scenario: sensors capture abnormal local pressure drops, triggering isolation valve closure to prevent gas diffusion. Project contractors can utilize Nexisense API interfaces to integrate data into GIS platforms for visualization monitoring and improved response speed.

User End: Metering Accuracy and Combustion Optimization

At industrial and commercial user ends, sensors are embedded in metering devices and combustion control systems to monitor low-pressure ranges (0–50 kPa). Combined with temperature compensation, accurate volumetric flow correction is ensured. Nexisense sensors support the HART protocol and are compatible with existing BMS systems, providing high-resolution data to optimize boiler combustion efficiency and reduce energy consumption.

A typical case is a chemical plant gas supply project: integrators deployed Nexisense sensors in dedicated regulating and metering cabinets, monitoring inlet/outlet differential pressure in real time and assisting PID controllers in regulating gas supply. Results showed a 20% improvement in system stability, with data logs supporting compliance audits. The solution emphasizes modular design, facilitating expansion to multi-user scenarios.

Pressure Sensor Selection Guide: Matching Gas System Conditions

Selection is key to ensuring sensor performance, requiring consideration of pressure type, range, accuracy, and environmental factors. Nexisense provides comprehensive guidance to help integrators optimize configuration.

Pressure Type and Range Selection

Gas systems involve absolute, gauge, and differential pressure. The gas source end prioritizes absolute pressure sensors (0–5 MPa) to accurately reflect tank conditions; transmission networks use differential pressure types (0–1 MPa) for flow calculation. The range should cover 150% of the expected maximum value to prevent overload. Nexisense series supports customized ranges from 0–100 kPa to 0–10 MPa to match specific working conditions.

Accuracy and Response Time Requirements

Accuracy affects control loop stability. ±0.25% FS or better is recommended for leak detection. Response time should be <50 ms to support high-speed sampling. Environmental factors include IP67 protection rating, resistance to -40°C to 85°C temperatures, and corrosion-resistant materials (such as 316L stainless steel), suitable for humid or corrosive gas environments.

Output Interface and Power Compatibility

Select sensors supporting 4–20 mA, 0–10 V, or digital interfaces (such as RS-485) for easy integration with SCADA or PLC systems. Power options include intrinsically safe types (Ex ia IIC T4) for hazardous explosive areas. Nexisense emphasizes EMC compatibility in compliance with IEC 61000 standards to reduce electromagnetic interference.

Integration Considerations: Ensuring System Compatibility and Reliability

Integrating Nexisense sensors requires attention to calibration, installation, and data fusion.

Installation and Calibration Best Practices

Install sensors in straight pipeline sections to avoid turbulence caused by bends. Use isolation diaphragms to prevent media contamination. Initial calibration should use standard pressure sources, with periodic recalibration (every 6–12 months) to ensure accuracy. Integrators should incorporate fault diagnostics such as self-check cycles to monitor sensor health.

System Compatibility and Data Integration

Support multiple protocols (Modbus RTU, Profibus DP) for easy integration into existing control systems. IoT vendors can utilize Nexisense SDK for cloud data aggregation. Redundant design is recommended: deploy dual sensors at critical nodes to enhance fault tolerance. During integration testing, verify linkage with valves and pumps to ensure closed-loop response <1 s.

Potential Challenges and Mitigation Strategies

High-pressure environments may induce vibration interference; use shock-absorbing brackets to mitigate. For data security, adopt encrypted transmission (AES-128) in compliance with GDPR requirements. Nexisense provides technical support, including on-site commissioning, to ensure seamless deployment.

Nexisense Advantages: OEM Customization and Bulk Supply

As a manufacturer, Nexisense focuses on B2B cooperation, providing OEM services including customized sensor housing, interfaces, and firmware to match integrator branding needs. With annual production capacity exceeding 100,000 units and flexible lead times (4–6 weeks), and ISO 9001 certification ensuring quality consistency. Customization includes specific range adjustments or integration of wireless modules, enabling contractors to rapidly iterate prototypes. Compared to generic products, Nexisense solutions reduce total cost of ownership (TCO) through long-life design (MTBF >10 years), reducing replacement frequency.

FAQ

Q1: What are the main types of pressure sensors in gas supply systems?
A1: They mainly include absolute, gauge, and differential pressure sensors, suitable for gas source regulation and pipeline flow monitoring.

Q2: How to select the appropriate range for high-pressure transmission networks?
A2: The range should cover 150% of the expected maximum pressure, such as 0–10 MPa, ensuring overload protection and compliance with system design standards.

Q3: How are Nexisense sensors integrated into SCADA systems?
A3: Through Modbus or Profibus protocols, supporting real-time data transmission and SDK-based custom algorithm integration.

Q4: What response time is required for leak detection applications?
A4: Response time should be less than 50 ms to capture micro-pressure changes and trigger rapid isolation valve response.

Q5: What does OEM customization include?
A5: Housing design, interface protocol adjustment, and firmware optimization tailored to integrator project requirements.

Q6: What about bulk supply lead time and quality assurance?
A6: Standard lead time is 4–6 weeks, ISO 9001 certified for consistency, with annual production exceeding 100,000 units.

Q7: What are installation considerations in hazardous explosive areas?
A7: Use intrinsically safe (Ex ia) products with safety barriers and comply with ATEX or IECEx standards.

Q8: How can pressure data optimize gas combustion efficiency?
A8: By combining temperature compensation and real-time volumetric flow correction, supporting PID control to regulate gas supply and reduce energy consumption.

Conclusion: A Partner in Building Efficient Gas Infrastructure

Nexisense pressure sensors support full-process optimization of gas supply systems through precision sensing networks, from source safety to terminal efficiency, providing reliable engineering solutions. Facing increasingly complex energy demands, integrators and project contractors can leverage our technical expertise to achieve system upgrades and cost control. Contact the Nexisense team to explore customized solutions and advance your next gas project together.