Monitoring your air compressor system is critical: if you rely on compressed air, you need to know that your system is working as efficiently as possible. A good monitoring system can help you keep costs down, reduce maintenance needs, and meet regulatory and business targets.
Just like air compressors and systems, monitoring will vary between businesses, depending on what is important to them. However, one thing that every compressed air system has in common is that at least some monitoring will be needed.
What are air compressor monitoring systems?
Monitoring systems can cover different implementations from a few dials that operators regularly check to an Internet of Things network combining data from multiple compressors and systems into a single dashboard, with remote monitoring and AI-driven analytics.
However, they all share a common purpose: to capture key data about compressor performance and the air system’s health.
Compressed air monitoring sensors
Sensors can be placed at key points to measure relevant data. This can include data like compressed air pressure, airflow, and temperature. Where dry air is important, they can measure dew point, helping prevent condensation. They can even measure vibration at key points in the system, detecting even the smallest tremors indicating a developing problem.
Transmitters and loggers
Because the sensors will be distributed through the compressed air system, and even across multiple sites, they usually transmit their data to a central point where it can be logged. Capturing this data allows in-depth analysis of use and performance, indicating when maintenance may be needed and providing insights that can result in savings through operational changes.
Controllers
Central controllers provide operators with an overview of the data, but can also help operate the system automatically. For example, Atlas Copco’s Elektronikon control systems are on-site control and monitoring systems. Because the system works around the clock, it can automatically automate responses to system changes, reducing energy costs.
Dashboards and alarms
The main purpose of monitoring is to put you in control. Systems like Elektronikon do that through dashboards, giving you customisable insight into your system from any computer or smart device, anywhere in the world. It also allows you to set alarms and notifications for specific changes. You can set it up if you want an SMS, email, or push notification of a specific change.
What are the benefits of compressed air monitoring systems?
Although you can choose to rely on things like performance and operator feedback, the continuous, accurate, and detailed data a monitoring system provides offers more control.
- Energy efficiency. Energy accounts for around 80% of a compressor’s lifetime costs. Monitoring helps you maximise efficiency, so you only pay for what your operations need.
- Proactive maintenance. The accuracy of monitors and sensors means that you can spot problems long before humans can detect them, so that you can make repairs. Conversely, they also help you avoid replacing components that are still within their working life.
- Extended equipment life. Reducing unnecessary usage and proactive maintenance reduces wear and tear and extends the life of your entire compressed air system.
- Better decisions. The comprehensive historical data you collect empowers you to make better decisions by providing an overview of performance that would otherwise be impossible to collect.
- Compliance. Whether meeting company environmental targets or externally assessed standards like ISO 8573, a monitoring system can assure you and regulators that your system is meeting the demanding standards you set.
What data should you collect?
A monitoring system should be customised for you; there is no point in collecting data that does not have meaning for your business. However, some datasets provide value to almost everyone.
Air pressure and airflow
You will have flow and pressure ratings, whether it is pneumatic tools, delicate packaging or processing operations. Tracking these can ensure your system is healthy and provide early warning of issues.
Power consumption
Identifying power use can help you keep your costs down. Increases that cannot be explained by increased productivity or new tools may also indicate a problem elsewhere that is forcing the compressor to compensate.
Leakages
A good system can identify leakage points. Significant amounts of air can be lost to leaks. Monitoring can indicate when a leak audit is due, and even the specific areas needing focus.
Dew point
Measuring the dew point is essential in industries such as food, pharmaceuticals, and electronics, where dry air is crucial. In other sectors, particularly those with larger systems, monitoring the dew point can help prevent condensation from forming within the system, which can lead to corrosion and damage to pipes and equipment.
Improve system reliability with the right system for your needs
Choosing the right system means balancing several factors. In addition to considering integration with your existing compressed air system and equipment, you may also need to consider how it can integrate with other monitoring systems so you can have a complete overview.
You also need to think about data retention and dashboard design, ensuring that your monitoring provides you with actionable insight, and not just an overwhelming set of graphs and tables – too much data can be just as bad as too little.
You should always include your monitoring system as part of your entire compressed air system, ensuring that you take care of things like staff training, routine maintenance, and calibration so you can get the best out of it.
Design Air has been installing monitoring systems since the most advanced was little more than a pressure dial on a compressor. Today, we partner with Atlas Copco to provide a scalable system that works with you, the way you want. If you wish to check on your compressor via a mounted panel, by using a phone app, or from an office on the other side of the world, we can design the monitoring system you need.
We have helped our customers save money on their energy costs, eliminate reactive maintenance callouts, and boost their productivity using intelligent monitoring systems. Contact us to learn how easy it is to do precisely the same.
