MEASUREMENT OF AIR CONSUMPTION
VIBRATION DIAGNOSTICS
AIR LEAK MEASUREMENT
Measurement of air consumption
Using a measuring probe, we measure the consumption of compressed air and electricity.
The process is fast and you get all the necessary information in graphs afterwards.
After measuring you will receive recommendations from us on how to reduce the cost of producing compressed air, which is up to 10 times higher than electricity.
Quit throwing money away!
Vibration diagnostics
The main goal of monitoring the vibrations of rotation machines is acquiring information on the operational and technical condition of the equipment in order to ensure strategic planning and maintenance management. An integral part of this process is the evaluation of the state and course of vibrations during the current operation. If you are interested in diagnostics, contact us. We offer periodic measurement and monitoring of bearing condition and detection of dynamic conditions. We also offer non-periodic measurement of problem devices or the implementation of diagnostics in the maintenance system.
The most common faults that increase vibrations:
rotor imbalance
misalignment of couplings, bearings and gears
mechanical release
bearing damage
gear wear
seizure
electrical faults
resonance
deformation
Air leak measurement
During the measurement campaign, a large number of companies from various industrial sectors were analyzed.
Result:
The average leakage rate was about 25 %. The proud “winner” had a leakage rate about 80%. In other words: From 100 kWh of energy, this company “blew” total of 80 kWh back into the atmosphere without any usage.
Leakage points in the overall compressed air system, ie in the distribution pipes or at the various connection points of the appliances, represent a significant cost factor. Leaks act as nozzles through which compressed air is expelled at tremendous speeds. Due to the fact that the air is invisible and odorless and does not pose a direct danger, its leakage is given about as much attention as, for example, the leakage of water from water pipes. The increased volume flow caused by leaks will increase the energy costs of producing compressed air.
By our calculations even a small leak with a diameter of only 5 mm (average diameter of leaks) in the network with air pressure of 12 bar has catastrophic consequences, leak of this size makes leakages of 58,5 l/s which will cost you over 16.000 € yearly.
The first step of the optimization and energy saving is the determination of the volume of escaping air.
Calculating the air leakage
There are lots of ways of determination or calculation of the volume of escaping air:
Using the volume of the tank
The volume leaking from the network with pressured air can be roughly determined by emptying the pressure tank. This is, for example, a measurement of the time during which the pressure drops by 1 bar. During measuring the tank is not being filled. Assuming that the compressed air flows isometrically, the volume of air escaping from the compressed air system can be determined using approximately the following formula:
| V= | Vb * (Pa-Pe) |
| t |
Vb = Volume of the tank
Pa = Initial air pressure
Pe = Final air pressure
t = Measurement time
Using the work cycle of the compressor
The second method how to determine the volume of leaks is using the work cycle of the compressor. This method can be used only with compressor with a fixed speed of rotation. The appliances in the network are switched off. Compressed air is still being used because of leaks and pressure in the network will decrease. The compressor has to replace the leaked volume. The total operating time T of the compressor is measured over the measured period. To obtain a representative result, the measured time it should include several switching intervals of the compressor.
How to find leaks:
- Soaping of compressed air connections
- Noise
- Ultrasonic measuring devices
As you can see, in most cases, the determination of the volume leaking and location of leaks is easy to find and repair is relatively cheap, especially when you consider that 70% of leaks occur in the last 30% of the compressed air network.
Extremely weak spots:
- Leaking “easy to disconnect” connections
- Leaking connection hoses to the respective compressed air appliances
- Using obsolete condensation drains (float drains, time controlled solenoid valves)
- Obsolete compressed air appliances (e.g. air powered tools)
- Broken seals on pneumatic controls and many other places