Compressed Air Monitoring

Why Compressed Air?

compressed air monitoring systems

In virtually every manufacturing facility in the world, in hundreds of industrial control applications, compressed air systems are used as power sources for tools and equipment. Most industrial facilities need some form of compressed air – from running a simple air tool to operating pneumatic controls.

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 undertake to do a feasibility study
  • 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, with or without wireless telemetry which can be controlled via a
  • touch screen, or a PC in your office, or via the internet.

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.