Detecting savings in compressed air

With price increases in the energy market, this factor is weighing more and more heavily on the cost of production. Those who have recently or soon seen their fixed contract expire therefore know what to do: identify savings. One of the most expensive sources of energy today is compressed air. But metris sensors from ifm electronic show you the way to more efficient use. 

Compressed air offers extraordinary potential for savings on your energy bill. "Because in the past, on the one hand, we have been too little concerned with correct sizing. Due to the affordability of energy, some extra margin was usually built in that is not actually necessary. On the other hand, leaks cause a lot of compressed air and thus energy to be lost. It is estimated that a third of the compressed air produced worldwide leaks out," says Marc Everaert, general manager of ifm electronic Belgium. And that doesn't just have its impact on energy bills. "The wrong compressed air flow rate will also hinder the proper functioning of your applications. Too little can prevent your products from moving sufficiently, resulting in a loss of quality. Too much, in turn, will needlessly increase energy consumption." 

Accurate measurement and monitoring

ifm electronic therefore developed its metris sensors 20 years ago to monitor compressed air consumption in pipelines. "At its launch, this was a particularly innovative product because it introduced a new measurement principle for compressed air measurement.
Instead of merely finding out whether there was compressed air or not, one can now accurately monitor the measurement of flow and consumption. Over the years, we have continued to fine-tune this. Today we combine four process values (flow, pressure, temperature and total consumption quantity) in one sensor. This makes them even today the most relevant sensors for applications," explains field Sales Support Geert De Pauw. And more interesting than ever to help companies nibble on their energy bills. "The operation is perhaps best compared to how the electricity meter works at home. Instead of at the main entrance, just behind the compressor, you place it at the entrance to each machine. That way you can perfectly monitor how compressed air consumption evolves in each installation."     

Moneo easily shows the way to savings potential

But just as a scale is not enough to lose weight, companies must then follow up on that data to reduce consumption. "Leaks cause no noise, no smell, no moisture and have never been a top priority in the past. But when you know that a leak as small as 2 mm at a pressure of 10 bar is already losing 6,000 euros ... In the current economic climate, we suddenly even see payback times that are shorter than the actual payment period on the invoice," De Pauw adds. To give his customers easy insight into exactly where the savings potential is in their production, there is moneo in addition to the TFT display on the sensor. Everaert: "You don't have to add any intelligence, nothing to program, just click and configure to turn the data from the metris sensors into clear dashboards. So couple the necessary alarms when anomalies occur and you'll be on your way to a lower energy bill in no time."

Also for other gases

An approach that need not be limited to compressed air, by the way. The Metris range has not only evolved in recent years to include more diameters (from DN8 to DN250), but can also analyze multiple gases. "Prices for gases such as oxygen and nitrogen also went into crescendo in recent months. Oxygen, for example, gets a lot of application in cutting processes. There, monitoring can be even more important to make about the right flow rate for reasons of cost, quality and safety."