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Smart scale energy solutions for compressed air systems

Reduce costs with improved system performance

Compressed air systems are complex systems and often "grow over time”. With constant system monitoring using meaningful KPIs, operators, supervisors and management are kept informed and constructive energy management is possible. As up to 85% of total costs of a compressed air system are energy costs, investment in measurement and system equipment pays off. We help you to reach your targets with our smart scale energy solutions for compressed air systems.

Compressor efficiency

The key to evaluate the compressor performance is the specific power or air consumption. It is the basis to:

  • Benchmark compressors and optimize their use

  • Optimize control system/load profile

  • Assess system/performance improvements

Apart from efficiency calculation the compressors power consumption indicates load/idling times which have a significant influence on energy costs. Another parameter of greatest importance for the compressor and system performance is the pressure.

System balancing and leakage

Typical plants have a leakage rate of 20-30% of the total compressed air production capacity. In well maintained systems this loss can be reduced to less than 10%. By using flow measurement at different points in the air systems balancing can be used to calculate leakage loss “in time” and thus:

  • Detect and repair disruptions or leakages

  • Avoid operation loss

  • Avoid longer compressor runtime

  • Reduce maintenance and increased unscheduled downtime

  • Avoid adding unnecessary compressor capacity

Air consumption

The allocation of energy usage to specific areas and processes is one of the key factors for energy management systems (e.g. ISO 50001) and precondition for transparent bookkeeping. The exact measurement of air consumption per unit of product is also helpful to optimize production processes. Furthermore the data are suitable for a carbon footprint evaluation.

Compressed air application - parameters

©Endress+Hauser

Applications

  • Simple products

  • Easy to select, install and operate

Technical excellence

Simplicity

  • Standard products

  • Reliable, robust and low-maintenance

Technical excellence

Simplicity

  • High-end products

  • Highly functional and convenient

Technical excellence

Simplicity

  • Specialized products

  • Designed for demanding applications

Technical excellence

Simplicity

Variable

FLEX selections Technical excellence Simplicity
  • F
  • L
  • E
  • X

Fundamental selection

Meet your basic measurement needs

Technical excellence
Simplicity
  • F
  • L
  • E
  • X

Lean selection

Handle your core processes easily

Technical excellence
Simplicity
  • F
  • L
  • E
  • X

Extended selection

Optimize your processes with innovative technologies

Technical excellence
Simplicity
  • F
  • L
  • E
  • X

Xpert selection

Master your most challenging applications

Technical excellence
Simplicity

Variable
compressor in a compressed air application ©Endress+Hauser

Define the right KPIs which help you to evaluate the compressor efficiency

Leakage of compressed air ©Endress+Hauser

Leakage of compressed air causes inefficient compressed air system performance

©Endress+Hauser
Monitoring the system with a data manager to get visualized process values ©Endress+Hauser

Monitoring the system with a data manager to get visualized process values

Pressure cleaning in the food productcion ©Endress+Hauser

Pressure cleaning in the food production

Service technician at a compressed air system ©Endress+Hauser

Service technician at a compressed air system

direct mass flow measurement in a compressed air system with t-mass 65I ©Endress+Hauser

Direct mass flow measurement in a compressed air system with Proline t-mass 65I

  • compressor in a compressed air application
  • Leakage of compressed air
  • Monitoring the system with a data manager to get visualized process values
  • Pressure cleaning in the food productcion
  • Service technician at a compressed air system
  • direct mass flow measurement in a compressed air system with t-mass 65I

Success stories

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    Steam monitoring pays off in less than two years

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    Build-up monitoring

    A water treatment plant in Germany faced the problem of unexpected downtime due to clogged water wells. With Heartbeat Technology build-up index the customer now monitors iron build-up in his process.

  • Life science factory in India Life science factory in India

    Transparency is essential for all calibrated instruments

    Making well-informed decisions based on calibration results that comply with all relevant quality and safety requirements is a key challenge in the life sciences industry.

  • Medical autoclaves performing sterilization at elevated temperatures using saturated steam Medical autoclaves performing sterilization at elevated temperatures using saturated steam

    Medical autoclaves

    New sensor technology automates recalibrations to reduce risk in batch sterilization. Learn More!

  • Picture of the water reservoir Marbach (Germany) Picture of the water reservoir Marbach (Germany)

    Smart monitoring system for potable water treatment

    With Netilion Water Network Insights, Oberzent's water masters now see all relevant data points of their water system on a cloud-based dashboard without having to drive to the plants.

Downloads

  • Energy solutions for compressed air systems

    With constant compressed air system monitoring using meaningful KPIs, operators, supervisors and management are kept informed and constructive energy management is possible.

  • Reduce your energy costs in utilities

    You can control only what you measure. Tailor-made energy solutions with rapid return of investment for steam, air, gas, oil, water, electricity, heating and cooling.

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