Compressed Air Monitoring

Why Compressed Air?

Compressed air is widely used in various industries and applications because it is a versatile and reliable source of power. Here are some reasons why compressed air is popular:

  1. Safety: Compressed air is a safe source of power because it does not produce any electrical sparks or heat that can ignite flammable materials.
  2. Cleanliness: Compressed air is clean and does not contain any contaminants, such as oil or grease, which makes it ideal for use in applications where cleanliness is critical.
  3. Versatility: Compressed air can be used to power a wide range of tools and equipment, from simple hand tools to complex machinery and robotics.
  4. Convenience: Compressed air can be stored in tanks or compressed air systems, which means that it is readily available when needed.
  5. Cost-effective: Compressed air is relatively inexpensive to produce and maintain compared to other power sources.

Overall, compressed air is a versatile, safe, and cost-effective source of power that is widely used in various industries and applications.


Compressed air monitoring systems

Compressed air monitoring systems are used to measure and monitor various parameters of compressed air, such as pressure, flow rate, and quality. These systems are used to ensure that the compressed air system is working efficiently and effectively, and to identify any potential issues before they become major problems.

Here are some common types of compressed air monitoring systems:

  1. Pressure monitoring systems: These systems measure the pressure of the compressed air in the system and can alert operators if the pressure is too high or too low.
  2. Flow monitoring systems: These systems measure the flow rate of compressed air and can help operators optimize the system’s performance by identifying any bottlenecks or areas of inefficiency.
  3. Quality monitoring systems: These systems measure the quality of compressed air, including the level of moisture, oil, and other contaminants. This information is used to ensure that the compressed air is suitable for the intended application and to prevent damage to equipment.
  4. Energy monitoring systems: These systems measure the energy consumption of the compressed air system and can help operators identify ways to reduce energy usage and improve efficiency.

Overall, compressed air monitoring systems are essential for ensuring the safe, efficient, and effective operation of compressed air systems.

expensive medium

Compressed air is an expensive medium; yet despite that, many compressed air systems are wastefully managed and with minimal system transparency. Capturing essential system performance data and monitoring critical air quality data is not only enlightening, but also enables future investments in compressed air systems to be fact-based and traceable.

leaks waste energy and money

This chart indicates the costs and energy loss associated with leaks. An undetected hole as small as 5mm can cost a plant €16,176 per year. Predictive leak detection and repair will result in substantial cost savings and system efficiency

12 bar pressure
hole dia. air leaks  € lost
1mm 1.8 l/s  € 480/ year
3mm 20.8 l/s  € 6,096/ year
5mm 58 l/s  € 16,0176/ year
10mm 235.2 l/s  € 63.360/ year

How are the leaks detected?

Our meter monitors air consumption to detect leakage areas in two ways

Method 1: when machine is in operation the meter compares the machine’s ideal air consumption to the actual air consumption. The difference indicates an air leakage.

Method 2: when machine is shutdown the meter continuously monitors the machine during shutdown. Any air consumption that is measured indicates an air leakage.

our meter can also monitor • Leakage per individual machine • Leakage per zones in a plant • Consumption per machine cycle • Consumption per shift • Consumption per zones in a plant • Verification of leak repair and system improvements

Dividing a plant into zones is key to leak detection In order for the meter to provide predictive maintenance information, a plant should be first divided into zones based on the number of fittings and potential leakage points. After sectioning a plant into smaller, more manageable zones, the meter is mounted in the supply line to the zone. The sensor will detect leakage areas based on the zone’s increase in air consumption over time or monitor air consumption when machines in the zone are shut down.

After a leakage area is detected, leak repair can occur quickly. The meter will target a leakage area by zone so that plant personnel can focus on a specific, smaller area, rather than search an entire plant for air leaks. With the zone identified, maintenance can quickly pinpoint the exact leak location and repair the leak. The best method for this is to use an ultrasonic acoustic detector and follow up with soap and water applied to the suspected leak.

We Offer Smart Solutions

We offer smart solutions

  • we discuss with you the details and condition of your compressed air network
  • we offer a starter kit suitable for your requirements (if you want to start on a small scale)
  • we offer complete systems that can include monitoring of consumption, pressure, dewpoint, oil content, particles, gases.

In other words, we cater for your compressed air system with simple or complex smart solutions and make the burden of looking after your compressed air, easy to handle.