Compressed air is one of the most expensive forms of energy and yet its consumption represents an unknown quantity in many industrial companies. Use of flow meters for compressed air measurement can help to significantly reduce energy costs and forms an important basis for investment decisions.
Why Monitor Compressed Air with Flow Meters?
- Ensure transparency
Precise billing based on individual consumption leads to greater cost transparency and highlights potential savings.
- Reduce costs
- Energy-efficient use of compressed air lowers ongoing operating costs. Use of flow meters enables early detection and correction of leaks.
- Safeguard quality
Continuous monitoring of the compressed air system safeguards process and product quality. Maintenance and repair work can be carried out on time and production downtime due to an unplanned system shutdown can be avoided.
- Increase energy efficiency
Compressed air monitoring is a key step towards an efficient energy management system in accordance with DIN EN ISO 50001
Compressed Air Cost Factor
Compressed air is the most expensive form of energy in production plants, comprising up to 20 % of the overall energy consumption. If compressed air consumption is not monitored, a key indicator for cost-reducing measures is wasted.
Leaks Result in High Costs
Between 25 and 40 % of the compressed air that is generated is lost through leaks. If hoses start to leak, the compressor running time is extended to compensate for the compressed air lost. Flow meters register even the smallest volume flows, thereby enabling reliable detection of leaks. This means that weak points can be promptly remedied and expensive compressed air losses can be minimised.
Identify Potential Energy Savings with the Right Energy Management System
Measurement of compressed air consumption represents a significant step towards a cost-conscious and efficient approach to energy consumption. While consumption of external resources such as electricity or water is precisely monitored, companies often lack knowledge about the consumption of internally-generated compressed air. Flow meters systematically record this data and play a key role in an energy management system in accordance with DIN EN ISO 50001.
Flow Meters Increase Process Reliability
Continuous compressed air monitoring with flow meters reduces the risk of production downtime due to an unplanned system shutdown. Even the smallest changes in volume flow point to potential weak points in a compressed air network, so maintenance work can be performed in good time, before this results in greater damage to machines and systems.
Why E+E Flow Meters?
The thermal measuring principle with contamination-resistant sensor element ensures outstanding long-term stability and a long sensor service life.
Factory adjustment at working pressure in a high-precision mass flow calibration facility ensures outstanding measurement accuracy.
Different flow meter versions are suitable for pipe diameters of DN15 to DN700 and pressures up to 40 bar (580 psi).
Innovative mounting concepts enable easy installation and removal of the flow sensor with only a short-term or no interruption to the flow.
E+E Flow Sensors with Thermal Measuring Principle
E+E flow meters operate on the thermal hot-film anemometer measurement principle. The volume flow is measured with a special thin-film sensing element (E+E flow sensing element). The heat dissipation caused by the air or gas molecules flowing past is recorded and readjusted with the aid of an integrated heater. The heating power required is a measure of the flow (=direct mass flow measurement). The volume flow is determined using the relationship of the pipe diameter and the sensor heating power.
Advantages of the measuring principle:
- High measuring accuracy and short response time
- Insensitive to contamination and mechanical influences
- Flow measurement independent of pressure or temperature
TIP: Combination with Dew Point or Pressure Sensor
Comprehensive compressed air monitoring systems monitor not only consumption, but also the dew point temperature and the operating pressure in the compressed air network.
The EE772 flow meter with hot tap valve enables a dew point or pressure sensor to be installed in the same measuring point without additional installation work.