Compressed Air Data Logging

Data Loggers are used to collect information on your compressed air system. This information can include pressure, flow rate, temperature and power consumed. Both a smaller or larger system, with a single air compressor or multiple compressors and other associated equipment can benefit from and be fitted with Data Loggers.

Energy Savings

Many of us in the industry have experienced a large push recently to prioritise doing our utmost to reduce energy consumption and increase energy efficiency. With the ever-increasing demand for energy globally and the detrimental impacts this is having on the environment, it has never been more imperative that we do all we can to consider and reduce our environmental impact. With energy prices on the up and the ‘energy crisis’ the UK has experienced in recent times, we have seen just how much energy savings and efficiency have gone up as a priority to compressed air users, as well as many others.

Companies should and are wanting to save as much energy as they can, not only to benefit the planet but also to reduce their energy costs. Data logging your compressed air system can provide you with the information you need to analyse your set-up and make the necessary changes to reduce your environmental impact and increase cost savings. Win-win!

Data logging your compressed air system and implementing the recommended changes is one of the best ways to lower your carbon footprint!

Data logging

A standard term of recording for a data logger is 7 days, during this period the data loggers will take recordings on your system, including but not limited to the areas mentioned above as well as the timescales your compressors run for. Further devices can be installed to measure your pressure dew point, temperature and the composition of your air.

Firstly, completing a data log at the beginning of a new system installation or the beginning of a production run can help gather hard data on what your system is producing, this is something known as the ‘baseline’.

The baseline can be compared to the manufacturer’s data sheets of each compressor to make sure that the compressors are producing what they should be.

Including data logging with your existing set-up can help prevent incorrect sizing decisions during any future upgrades you plan for your compressed air system.

What are the benefits of data logging?

First, the data we record helps us to understand how many kilowatts (kW) of power are being consumed and in turn, the number of kilowatt hours (kWh) your system is using. kWh is what your energy provider will be charging you for. As part of the data log, we can provide you with the amount of kWh it takes to power your processes, this will then provide you with how much it is going to cost you to run this system every year.

Second, regular data logging can then help us to provide you with information about your processes and how efficient they are. If your system is performing below the manufacturer’s specification, there is likely a reason. Determining and actioning this early can help prevent costly repairs and/ or downtime.

Third, we can also determine if you are using more or less air than when you started working with your compressed air equipment set-up. In turn, this can assist with indicating if there are any leaks and/ or if previous leaks have now been rectified.

Fourth, the biggest upside to regular data logging……. Locating issues. Looking at the data produced by the loggers we can determine if there are any anomalies in air consumption at a specific time during the day or night, identifying these problems is the first step to fixing them.

When should I complete Data logging?

Prior to replacing compressors with bigger or smaller models to ensure any possible upgrades are considered effective.

After any changes have been made to your existing system, verify how much impact the updates have made. This could be a reduction in air usage, a reduction in pressure or a reduction in downtime, all leading to a saving of energy and money!

Ongoing, data logging is important to maintain at regular intervals for peace of mind that your system is running to its best efficiency and capability, as well as to identify any leaks within your compressed air systems.

Here is an example:

Air Energy Limited previously logged an injection moulding facility for 1 week and determined that the customer was using a 22KW machine just to feed leaks all day, every day. We pointed out to the customer that if they made some changes, they could be saving up to £27,000+ a year. Can you imagine what you would do with that?

Suggested improvements

The most important step after having your compressed air system data logged is implementing the changes required. One of the changes we have implemented on a lot of sites is installing a control system for multiple compressors.

When there is one main compressor that does most of the work, and multiple smaller compressors at the point of use, linking them together and using a controller to deliver the amount of flow and pressure your system requires is very effective.

For example, we have a customer who had seven compressors on site, all running individual processes. We were asked to complete a data log on their compressed air system and once data was logged, we determined there was potential for a lot of energy savings. Our engineer installed a central compressor controller and linked the pipework together. Upon completion, only 3 of the compressors ever run at peak demand which lead to reduced energy usage on site and removed 25kw of compressor power from this site’s energy consumption.

If you are interested in having your compressed air system data logged, with our top-of-the-range data logging equipment, to have more system control and reduce the inefficient operation of machinery, please feel free to get in contact with our knowledgeable team!

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