Consumption/Air Flow Monitoring

Actions Benefits Compressed air monitoring Leakage Detection, Waste Elimination, Energy cost reduction Cost effectiveness of compressed air system improvement. Heat Treating Air flow monitoring in heat treating furnaces to improve quality. Wastewater Treatment Monitoring and adjust the air flow into aeration tanks to control the critical D.O. level. Fuel Cells Air flow monitoring to control the efficiency of fuel cell power plants. Pump Manufacturing Air flow monitoring to test pumps for quality control during manufacturing. Metals Recovery: Air flow rate is critical in forming bubbles during the process that capture precious metals that otherwise are not recoverable. Spray Drying Air flow monitoring, so that components dry uniformly in white appliances, pharmaceutical, food processing, fertilizer and chemical industries. Brewery Malt Germination: Air flow monitoring for energy saving. Remediation Meter the air intake used to detect contaminated soil. Powder Painting Monitor air flow, including turbine air, atomizing air and shaping air to control paint quality using robotics. Pulp and Paper Improve product quality by monitoring drying air flow.

Monitoring the use of compressed air 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 (C400) 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 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.

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 flowrate of the compressed air during this cool down period to minimize thermal stress and maximize the reduction of the cooling time.

Application parameters

User – Various steam/electric stations

Media –  Compressed air

Line Size  – 3 inchSch. 40

Flow Range  – 0.5 to 20 SCFM

– [0.01 to 0.57 NCMM]

Pressure Range – 10 psig [0.69 bar(g)]

Temp. Range  – 40º to 100ºF

– [4.4º to 37.8ºC]