Utilities Monitoring
Compressed-Air Monitoring: Finding Leaks and Unnecessary Consumption
Combine flow, pressure and operating schedules to investigate compressed-air demand.
High compressed-air demand does not identify a leak by itself. Monitoring should separate legitimate production use, unnecessary use and leakage before assigning a repair or savings estimate.
Map the system and operating periods
Identify compressors, storage, distribution branches and major consumers. Record shift schedules and equipment that legitimately uses air outside production. Choose measurement boundaries that can isolate a useful area. A plant-wide flow value may reveal unusual demand but cannot pinpoint which fitting or machine is responsible.
Measure flow and pressure meaningfully
Specify meter range, pressure conditions and whether flow is reported at actual or reference conditions. Confirm installation requirements with the supplier and site specialists. Trend pressure with flow and compressor state. A pressure drop can arise from demand or restrictions as well as leaks, so interpret the signals together.
Investigate residual demand
Review approved non-production periods while accounting for known consumers. Use a suitable leak survey to locate suspected sources rather than relying only on the total flow trend. Tag findings, assign repairs and track completion. Isolation tests and work on pressurised systems must follow the site’s authorised procedures.
Confirm the benefit after repair
Compare before and after demand under similar pressure and production conditions. Check that reduced flow did not come from a schedule or setpoint change. Translate demand reduction into energy impact using measured compressor behaviour where practical. Report assumptions and avoid promising a fixed percentage saving before the survey.
FAQ
Does air use during shutdown always mean leakage?
No. Some equipment has legitimate demand; account for those consumers before estimating leakage.
Technical References
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