Flow Monitoring for Air Compressors
Serving customers throughout the Central Belt and Scotland, including Glasgow, Edinburgh, Dundee, Fife, Stirling, and Perth, our certified engineers use advanced flow monitoring technology to visualise your compressed air usage and identify waste.
Contact us today to speak to our experts about flow monitoring. Our team is ready to help you stop paying for air you do not use.
Flow Monitoring for Air Compressors
Did you know that without measurement, your compressed air system is a financial “black box”? Most industrial sites in Scotland have no visibility into where their air goes, leading to wasted energy and unstable production.
The good news is that we can install precision flow monitoring, identify artificial demand, and reduce your electricity bills.
Benefits of Our Flow Monitoring Services
Installing permanent or temporary flow measurement provides immediate operational data. This drives smarter decisions and lowers overheads.
Improved Energy Efficiency
- Identify Artificial Demand: See exactly where high pressure is causing tools to consume more air than necessary.
- Reduce System Pressure: Safely lower pressure by 1 bar to reduce energy consumption by approximately 7%.
- Avoid Oversizing: Use accurate demand profiles to buy exactly the compressor capacity you need, avoiding costly capital expenditure on oversized units.
Lower Maintenance and Operating Costs
- Preventative Alerts: Detect changes in flow that indicate failing components before they break.
- Leakage Baseline: Instantly see if your “weekend baseline” (leakage) increases, triggering maintenance only when needed.
- Extended Equipment Life: Optimise compressor cycles to reduce motor run hours and wear.
Enhanced Equipment Performance
- Stable Pressure: Ensure critical machines receive the correct flow volume to maintain product quality.
- Air Treatment Validation: Confirm dryers and filters are operating within their rated velocity to prevent moisture carryover.
- Reduced Production Downtime: Identify flow restrictions or pressure drops before they stop the line.
Regulatory and Compliance Support
- ESOS Phase 4 Ready: Replace estimates with verifiable metered data for your Energy Savings Opportunity Scheme audits.
- ISO 50001: Meet requirements for continuous monitoring of significant energy uses.
- ISO 11011: Align with the international standard for Compressed Air Energy Audit assessments.
Our Flow Monitoring Process
We do not just sell sensors. We deliver a complete data solution. Our comprehensive approach combines technical installation with expert analysis to ensure you get actionable data.
Step 1: Initial System Assessment
Visual and Technical Inspection
Our engineers visit your site to determine the optimal sensor location. We check:
- Pipe diameters and materials.
- Available straight-pipe runs (laminar flow requirements).
- Moisture content (wet vs. dry side).
- Signal strength for wireless connectivity.
Technology Selection
We select the right sensor for the specific application:
- Thermal Mass Meters for high-precision demand tracking on the dry side.
- Pitot Tubes for robust measurement at the compressor discharge (wet side).
Step 2: Advanced Installation Techniques
Hot Tapping for Zero Downtime
We understand that production cannot stop. Our team uses “hot tapping” drilling tools to install probes into pressurised pipes safely.
- No system depressurisation required.
- Secure installation using safety chains and retention cables.
- Flow conditioners are installed where straight-pipe runs are limited.
Sensor Configuration
We configure the sensors to measure Mass Flow. This accounts for air density and provides data in Standard Cubic Feet per Minute (SCFM) or Normal Cubic Metres (Nm³), complying with ISO 1217 standards.
Step 3: Data Integration and Reporting
Connectivity
We integrate the sensors into your existing infrastructure:
- Atlas Copco SMARTLINK: Centralise flow, pressure, and dew point data for Remote Monitoring via mobile or desktop.
- Mixed Fleets: Use IIoT gateways to pull data from Modbus RTU/TCP meters into a unified dashboard.
- BMS Integration: Feed data directly into your Building Management System.
Actionable Insights
We help you interpret the charts to find the savings:
- Pinpoint specific production shifts causing demand spikes.
- Quantify exact leakage costs during non-production hours.
- Validate the performance of air dryers and filters.
Why Flow Monitoring Matters: The Hidden Costs of Unmeasured Air
Operating a compressed air system without flow meters is expensive and risky. The consequences of “flying blind” directly impact your bottom line.
Unchecked Leakage
A single 3mm leak costs over £1,000 per year. Without a flow meter establishing a baseline, these leaks grow unnoticed, forcing your compressor to work harder.
Artificial Demand
Every 1 bar (14.5 psi) of excess pressure increases energy use by 7%. It also forces unregulated tools to consume more air. Flow monitoring reveals the exact pressure required to sustain production, allowing you to trim this waste.
Equipment Damage
Undersized dryers lead to high air velocity. This reduces residence time, causing dew point spikes and water contamination in your network. This damages pneumatic tools and ruins end products.
Dryer Purge Failure
Desiccant dryers should consume 15–20% of air for purging. A stuck valve can push this to 40% or more. Monitoring the wet and dry sides of the system identifies this massive waste immediately.
For a deeper understanding of system parameters and sensor types, read our Guide to Air Compressor Monitoring Systems.
Frequently Asked Questions (FAQ)
None. We use hot-tapping tools to install probes while your system remains live and pressurised. Your production continues uninterrupted.
Most sites cover the hardware cost within 6 to 12 months. Identifying and fixing a single significant leak or reducing pressure by 1 bar often pays for the system immediately.
Yes. Our external flow meters and universal data loggers work with any compressor brand, age, or pipe size.
Not necessarily. A master flow meter on the main header provides the most critical site-wide data. We add individual meters for granular analysis of specific production lines if needed.
Take Action Today
Do not let inefficiency drain your budget and compromise your system reliability.
Our professional flow monitoring services provide the data you need to reduce energy bills, ensure compliance, and extend the life of your equipment.
Contact Design Air (Scotland) Ltd today to arrange a site survey.