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OPTIMISATION OF COMPRESSED AIR Compressed air optimisation for efficient compressors & air systems

Jul 13, 2022

Compressed air is used in many different manufacturing processes and activities. Consumption costs of compressed air is quite high and therefore it should be carefully measured and optimised for higher yields. This article explores the different ways to optimise the use of compressed air.

Compressed air is an essential energy source for various industrial applications, processes and operations. Whether it is a pharma facility, a cement plant, or industries like automotive or textile, efficiently utilising compressed air is crucial. While air is free for everyone, compressed air incurs high consumption costs, so proper measurement and optimisation of this fuel are necessary.

It is used for conveying material in the industry, controllers and actuators, tool powering applications and even automating equipment. In any such application, moisture in the compressed air can lead to system failures or inefficiencies. Furthermore, if users are not aware of compressed air management and measurement techniques, it can create annual monetary losses to the facility & wastage of the compressed air too.

Advanced air meters

Compressed air management can be tricky, especially for inexperienced personnel. New and advanced compressed air meters are used to tackle such challenges and improve the efficiency of compressed air applications. These meters have been a great advantage to drier manufacturers or energy auditors.

New generation compressed air meters come with various benefits. For example, they allow for targeted implementation of environmental management (as per ISO 50.001), monitoring leaks in your compressed air system and carrying out a peak load analysis to determine whether you are generating compressed air of sufficient capacity.

One such advanced air flow meters is the testo 645x series, which has an ‘all-in-one sensor’ that records compressed air consumption, temperature, and pressure, eliminating the need to conduct separate pressure measurements. Instead, it uses the calorimetric measuring principle.

In short, these meters enable you to measure compressed air consumption accurately while saving energy and reducing costs.

Advantages of advanced compressed air meters

  • 4 measurement parameters with just one instrument: Flow rate, totaliser, temperature, operating pressure

  • Clear overview: Direct compressed air monitoring with simultaneous display of 3 measurement values (standard TFT display)

  • Best system integration: Two analogue outputs 4 to 20 mA

  • Integrated measuring section prevents measurement errors & ensure maximum measuring accuracy

  • Quick to use & easy installation

  • Measurement according to the calorimetric principle: No pressure loss during measurement

Ultrasonic leak detectors

Like compressed air meters, testo ultrasonic leak detector LD pro is a very efficient & reliable instrument for detecting, assessing, and stopping leaks in your air systems. Most importantly, documenting the loss of compressed air is convenient and saves costs without delay.

It comes with headphones and state-of-the-art camera technology, with which you can carry out acoustic leak detection by pointing the instrument at the subject and displaying leaks in an actual image. All relevant & necessary readings, measurement values & loss calculation is visible on the instrument display screen.

Advantages of ultrasonic leak detectors

  • Acoustic leak detection using headphones and the sound funnel

  • Integrated camera for visualisation of leaks

  • Simplified documentation and optimal assessment of compressed air loss with leaks highlighted in the real image

  • Integrated cost calculation: Leak costs are calculated and can be read on the display

  • USB port for easy transfer of measurement data from the leak detector to the PC

  • Create reports in accordance with ISO 50001 with ease, and manage them conveniently using the Testo-Leak software

  • Easy to operate via touchscreen and robust membrane keypad with intuitive interface

  • Ideal for use in industrial environments for its robust housing and light weight

Dew point transmitters

While working with compressed air, the presence of humidity and moisture can cause damage to the components or impair the quality of the end-product and hence, are considered undesirable in the air. Therefore, proper monitoring and control technology is essential for such critical applications.

Testo 674x dew point meter is designed to measure the humidity trace in compressed or dry air to prevent damage, saving a lot of money invested in the operation and reducing the cost of installing absorption dryers. In addition, the required air quantity can be optimised to ensure there is zero wastage of the fuel.

Advantages of dew point transmitters

  • High accuracy: Measure humidity with a high degree of precision

  • Scalable analogue output: The dew point transmitter converts the measured values into a standardised electrical signal, whereby the analogue output can be scaled as required (4 to 20 mA)

  • Alarm plug with 2 integrated switching outputs (optional)

  • The testo 6743 dew point transmitter features a compact and user-friendly design

  • The housing can be rotated by 350°, enabling optimum alignment of the display

  • Display with operating menu: convenient operation and on-site read-out of readings

Facility managers and engineers working on high end systems must be aware of the potential threats in terms of leakages, humidity traces and fuel losses to optimise the entire process and ensure healthy working condition of the machines. Testo can surely extend its expertise & consultation to all the users to improve their operation as well as output.

Courtesy: Testo

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