Monitoring airflow within compressed air systems is a critical practice for industrial facilities. Robust monitoring ticks a number of boxes such as; enhancing energy efficiency, reducing costs, improving system performance, ensuring product quality and minimising environmental impact. With the SICK FTMg flow sensor, you can monitor airflow and detect leaks simultaneously. Installing an FTMg will contribute to the overall performance and efficiency of your industrial plant.
In this interview with Nick Hartley from SICK, we take a closer look the the FTMg flow sensor and discover how monitoring compressed airflow will highlight the useful information that site engineers need to improve processes, reduce unplanned maintenance and lower the cost of energy use.
What we know about compressed air systems.
1. Energy Efficiency
Compressed air systems are significant energy consumers in industrial settings, often accounting for 20% to 30% of a facility’s total electricity usage. However, without proper monitoring, up to 30% of this compressed air can be wasted due to leaks and inefficiencies. By continuously monitoring airflow, operators can detect leaks early and address them promptly, preventing unnecessary energy loss. This proactive approach can lead to energy savings of 20% to 30%.
2. Cost Savings
Reducing energy waste directly translates to lower energy bills. For instance, a facility spending £1 million annually on energy could save up to £180,000 per year by implementing effective airflow monitoring and leak detection. Additionally, early detection of issues through continuous monitoring can prevent major breakdowns, reducing maintenance costs and minimising downtime.
3. Improved System Performance
Consistent and reliable airflow is essential for the smooth operation of pneumatic tools and machinery. Monitoring air flow helps maintain the required air pressure and flow rate, ensuring that the system operates within its optimal range. This prevents overloading, which can cause wear and tear, leading to frequent repairs and replacements.
4. Enhanced Process Efficiency
Monitoring airflow allows for better balancing of pneumatic devices and automation of manual tasks. By ensuring that each device receives the optimal amount of air, processes can run more efficiently and effectively. This not only improves productivity but also enhances the overall quality of the output.
5. Environmental Impact
Efficient use of compressed air reduces energy consumption, which in turn lowers greenhouse gas emissions. This contributes to a smaller carbon footprint and supports sustainable industrial practices. Monitoring also helps in the efficient use of resources, further promoting environmental responsibility.
6. Compliance and Safety
Many industries are subject to regulations regarding energy use and emissions. Monitoring airflow helps ensure compliance with these regulations, avoiding potential fines and legal issues. Additionally, maintaining proper airflow prevents dangerous conditions such as over-pressurisation, enhancing the safety of the compressed air system.
7. Data-Driven Decisions
Continuous monitoring provides valuable data that can be analysed to improve system performance and efficiency. This data can be used for predictive maintenance, allowing operators to plan maintenance activities based on actual system conditions rather than on a fixed schedule. This approach helps avoid unexpected downtime and extends the lifespan of the equipment.
For more on SICK FTMg see the featured products below, or head to RS and view the complete range.
SICK resources for FTMg
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