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Compressed air leaks- Primary onboard measures have always been included with every air compressor and dryer to assist service staff in determining whether or not repairs are required. It was usual in the past to have only analogue temperature and pressure gauges and a set of hour metres to detect when maintenance was required, all of which were crucial factors to track for compressed air systems. A technician might also examine the incoming voltage and current with a simple clamp-on ammeter and a voltmeter to ensure everything is in working order. However, the compressed air industry has evolved, and better tools for the “toolbox” are now available to assist with system measurement & monitoring.

Monitoring Compressed Air Flow

Industrial air compressors consume more electricity than most other machines. They frequently account for up to a third of an industrial plant’s total energy consumption. A thermal mass flow metre can be used in energy management systems to help determine the best number of compressor units for a specific operation at any given time. This is established by determining excessive air consumption and compressed air utilization.

An ultrasonic acoustic detector, gas leak detection compounds, and thermal mass flow metres can all be used to detect compressed air leaks. Thermal mass flow metres can assess the extent of the leak or leaks and quantify the wasted energy, while ultrasonic acoustic detectors and gas leak detecting compounds can pinpoint the leaks’ sites. Digital Thermal mass flow metres help determine where compressed air is used and the relative amounts of leakage.

Electronic Compressor Controls

Modern compressors include sophisticated loT enabled electrical controls, many with digital touch screen displays, and some even track internal conditions over a period of time for use in local troubleshooting problems. The most recent and advanced controllers monitor a wide range of internal variables and provide configurable alarms connected to the local internet or configured to send text messages when circumstances deteriorate. In addition, some high-end compressors now come with pre-programmed web pages and even cell modems that send data back to the OEM for study; this data is frequently provided to users on a subscription basis. Maintenance employees may access these settings remotely using a smartphone instead of walking to the compressor room.

Thermography

Temperature issues frequently hamper the reliability of air compressors and dryers. However, infrared temperatures (IR) detectors are pretty inexpensive and can be used to measure and track crucial temperatures in compressed air leaks. In addition, there are more advanced, low-cost IR cameras available that provide users with a comprehensive thermal image of operational equipment. With a fast glimpse at a thermal signature, a camera can reveal how electrical components, compressor coolers, motors, and bearings operate.

Leak detection using ultrasound

Compressed air leaks can squander up to 30% of a compressor’s output, making them a substantial waste energy source in an industrial plant. But how can leaks be detected if they aren’t visible? The best technique to identify compressed air leaks, according to most experts, is to utilize an ultrasonic acoustic detector. This device detects high-frequency hissing sounds associated with air leaks and employs a range of visual and aural indications to pinpoint their position.

Due to its capacity to adapt to several leak detection scenarios, ultrasonic leak detection is one of the most versatile types of compressed air leaks detection. Its acoustic sensor zeroes in on noise variations to find leaks of medium to big size. Ultrasounds can locate leak sources by focusing on the loudest sound level because they are short wave signals that are directional in transmission. Because the signals in the audible range are filtered out, ultrasonic detectors are often unaffected by background noise.

Sensors for Remote Monitoring

The correct method to reduce inefficiencies can pay off big time. For example, savings of up to 30% of the energy input to the air compressor are not uncommon. These savings are achieved by selecting the most efficient air compressor at the outset, guaranteeing proper air system design, and continuing to operate and maintain the system efficiently. It also entails augmenting the most cutting-edge technologies available and ensuring that simple leakage prevention procedures are implemented.

Monitoring compressed air usage is a good place to start, especially since the correct layout of the pressurized system and piping material is often overlooked. When this occurs, the air conditioning system works overtime, wasting electricity. Therefore, before any system adjustments occur, monitoring sensors should be installed to identify problem areas and provide quantitative data on what needs to be fixed.

Personal preference determines which monitoring sensor is utilized. Data can be captured using an analogue sensor or a wireless sensor that sends information to a cloud-based monitoring platform. Pressure, humidity, and flow should be measured to develop a complete compressed air system health profile.

Some wireless sensors explicitly designed for compressed air system monitoring give the necessary measurements and report crucial data to cloud-based monitoring platforms and provide real-time data access at all times. Furthermore, the most up-to-date technology notifies users when readings go outside of a desirable performance band.

As part of a compressed air leaks assessment, it’s often ideal to have a certified compressed air expert determine what sensors are needed and where they should be put.

Data from flow sensors can reveal a variety of issues of Compressed Air leaks :

Flow sensors installed in the precise areas in a compressed air system will detect potential compressed air leaks, excessive or inappropriate compressed air usage, and the overall facility and department demand. Monitoring the artificial need for air during idle (non-production) times is the most remarkable technique to check for system leaks. The more artificial demand there is the more leaks in the system. Analyzing data also determines the pipe’s health. Pipes will corrode and clog without ever displaying indications on the outside. Poor flow values indicate that the tube has started to deteriorate.

Contact us at Stopleakloss today to learn more about the detection of compressed air leaks and how we can assist you in identifying energy savings and system leaks.