Compressed air is widely used in various industries for powering tools, equipment, and processes. Accurate measurement and monitoring of compressed air is crucial to ensure efficient and reliable operation, minimize energy consumption, and reduce operating costs. Here are some common applications of compressed air measuring and monitoring:

Compressed air flow measurement: Measuring the flow rate of compressed air is essential for monitoring consumption, detecting leaks, and optimizing system performance. Flow meters, such as orifice plates, Venturi meters, thermal mass flow meters, and ultrasonic flow meters, can be used to measure compressed air flow in pipes, hoses, or other parts of the compressed air system.

Compressed air pressure monitoring: Monitoring the pressure of compressed air is important to ensure that it is within the required range for specific applications. Pressure transducers or pressure sensors can be installed at various points in the compressed air system, such as at the compressor outlet, after the dryer, or at the point of use, to measure and monitor the pressure in real-time. This helps in identifying pressure drops, detecting abnormalities, and optimizing system performance.

Compressed air quality monitoring: Monitoring the quality of compressed air is critical in applications where the air comes into direct contact with the product, such as in food and beverage manufacturing, pharmaceuticals, and electronics. Compressed air quality can be monitored for parameters such as moisture content, oil content, particulate matter, and microbial contamination using appropriate sensors, analyzers, and detectors.

Compressed air energy monitoring: Compressed air systems can be energy-intensive, and monitoring energy consumption is essential for identifying potential energy-saving opportunities. Energy meters, power monitors, or data loggers can be used to measure and monitor the energy consumption of compressors, dryers, filters, and other components of the compressed air system. This data can be used for energy management, bench marking, and identifying areas for improvement.

Compressed air leak detection: Leaks in compressed air systems can result in significant energy waste and increase operating costs. Leak detection systems, such as ultrasonic leak detectors or acoustic sensors, can be used to detect and locate leaks in compressed air pipes, fittings, valves, and other components. This helps in identifying and repairing leaks promptly, thereby reducing energy waste and optimizing system efficiency.

Compressed air usage monitoring: Monitoring the usage of compressed air is important to track consumption patterns, identify inefficiencies, and optimize system performance. Usage monitors, such as flow meters or energy meters, can be installed at the point of use or at specific equipment to measure and monitor the consumption of compressed air. This data can be used for demand-side management, identifying over-usage, and implementing energy-saving measures.

Compressed air system performance monitoring: Monitoring the overall performance of a compressed air system is crucial for identifying inefficiencies, optimizing system operation, and improving reliability. This can be achieved through a comprehensive system monitoring solution that includes monitoring of compressed air flow, pressure, quality, energy consumption, and other relevant parameters. Data can be collected, analyzed, and visualized using advanced software or monitoring platforms to provide insights, alerts, and reports for system performance evaluation and optimization.

In conclusion, compressed air measuring and monitoring applications play a vital role in ensuring the efficient and reliable operation of compressed air systems. By accurately measuring and monitoring parameters such as flow, pressure, quality, energy consumption, and usage, industries can optimize their compressed air systems, reduce energy waste, minimize operating costs, and improve overall system performance.

Monitoring compressed air usage within a facility.
To determine the optimum number of compressors that need to be in operation at any given time so that the facility load is satisfied, a measuring station that includes a controller(D300) and a consumption sensor (S401) is installed so that the consumption of compressed air is monitored continuously and automatically determines the optimum number of compressors to handle the facility demand.

Power and Energy Compressed Air

Power plants typically require scheduled maintenance to be performed on the turbine generators. The maintenance outage duration is extended by up to sixty (60) hours or more to allow the turbine to cool down. This results in extending the outage duration in both generation time and reduced revenues for this extended period. In today’s Power Industry, the increased demand for power places an even greater demand on the power generator to minimize downtime associated with plant maintenance outages. By developing ways to reduce the outage time, a plant can maximize its generation output, which translates into maximum availability and profit.

Power Generation Application
Forced draft cooling air is supplied to the H.P.and L.P. housing from a compressed air main pipeline running adjacent to the turbine generator. The H.P. and L.P. housings are supplied with forced air via two lines that are tapped off the compressor air mains. The air needs to be injected slowly and increased to its maximum flow slowly to reduce unnecessary thermal stress to the turbine blades. The use of symmetrical air inlets with entries at the top and bottom of the turbine casing provides uniform cooling by proportioning the flow to the top and bottom casing halves. It is possible to eliminate the differences in temperature between the top and bottom of the turbines which arise during natural cooling and could cause turbine damage. It is necessary to accurately measure the flow rate of the compressed air during this cool down period to minimize thermal stress and maximize the reduction of the cooling time.

Dew Point Measurement Applications in Trains

Pneumatic systems in railway applications are vulnerable to water condensation as a result of the cooling of compressed air. This water tends to cause corrosion, degrade lubricants and freeze in cold weather, causing malfunction and damages in brake systems and other pneumatic devices as well as pneumatic components (cylinders, valves). For this reason regular measurement of dew point is essential.

Sigma provides a user friendly Sigma 520 handheld dew point meter  for these measurements and increased operational safety.

Compressed Air Flow Meters for Train Air Brake Leakage Monitoring



Note: Please bear in mind that although many applications look similar, depending on the peculiarities of each case the result might be different.

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