Air Compressor Monitoring System


Air Compressor Monitoring System



As manufacturing capacity increases, compressed air capacity needs to be expanded in order to support the increased demand. You can achieve this by upgrading the existing system to provide additional air capacity or by installing a separate system. The power consumption of an air

compressor can be high even when it is idle. Additionally, old compressors can be inefficient. Because of this, they use more power.

All businesses are affected by rising energy costs, tough economic times, and the need to reduce costs. These factors are driving increased

interest in energy reduction measures and technologies. Most industrial facilities are looking at ways to reduce their energy consumption by reducing their use of compressed air systems, a very expensive utility.

Monitor the following parameters of an air compressor based system to ensure that excessive power is not being consumed by it:

  • the on/off period,
  • the load/unload period i.e. the loading pattern,
  • the pressure using the pressure sensors,
  • the air flow (cfm) using the flow meter,
  • the humidity
  • the power consumption.


Furthermore, operation and maintenance department can perform preventive maintenance by monitoring these parameters by evaluating compressor performance through control system and monitoring system. Compressed air monitoring equipment which includes

  • Air consumption monitoring using flow meters.
  • Compressed air sensor for Temperature.
  • Compressed air quality monitoring using dew point meter.
  • Compressed air pressure sensor for system pressure.
  • Air compressor sensor for Discharge Air.
  • Energy Meter for compressor.
  • Compressed air data logger.
  • Other Compressed air system monitoring tool.


Application of Air Compressor Monitoring Solutions

These tools should be considered when you evaluate compressed air system determining the efficiency and power consumption of air compressors:

  • An air compressor data logger with network capability (remote compressor monitoring) using high-speed wireless, cellular, modbus, Canbus, Profibus, Ethernet data transmission that continuously logs and records air compressor parameters as well as taking multiple inputs for extensive data analysis.
  • Easy-to-use data logger software, displaying and displaying parameters as they are measured by the data logger in form of graphs
  • Integrated active power meter with the ability to measure power (kilowatt-hours and megawatt-hours), voltage, and current.
  • An air compressor temperature sensor measures the air compressor’s temperature value after each compression stage.
  •  Each air compressor should be equipped with a pressure sensor that measures pressure per square inch
  • Each Compressed air system should have pressure sensor’s at utility point to measure pressure drops and estimating leakage.
  • Dew Point Meter to measure the amount of water vapor within the air compressor.
  • Flow meter for Compressed air Consumption Monitoring.
  • Controller to manage air compressor air supply to the system.
  • Compressor on/off time for form a basis on compressor uptime w.r.t. air production.


Permanent Monitoring and Measuring of Compressed Air Systems

Over the course of several weeks or months, a permanent monitoring system can provide an extremely solid baseline for industrial plants. In

addition, it can be used to examine and quantify data such as weekend leak rates, as well as different loads based on more detailed profiles of production days and equipment operation.

A robust baseline profile allows an audit to better identify an array of corrective measures, such as storage changes, piping changes, control systems, or leak repair – and quantifying the ROI for each measure and prioritizing them with budgets or timelines.

When operating, installing, purchasing, or designing compressed air products, the main objective is to achieve optimal compressed air system performance and peace of mind defined by efficiency, reliability, and air quality. All stakeholders in the compressed air industry, from the air compressor manufacturer to the distributor to the end user, need to be aware of and work towards these goals.

Whether you’re in retail or manufacturing, compressed air is essential for your daily operations. You need equipment that meets your growing demands, since it’s probably the largest investment you’ll ever make.

By utilizing an advanced air system monitoring, logging and regular audits of your air equipment, you can intelligently determine if your air compressor is meeting those needs.

Your air compressor can be monitored in real-time with compressor services monitoring equipment. Business decisions can be made in a matter of seconds, and adjustments can be made for optimal performance and to meet requirements during long-term use of compressor products.

Decide immediately how to optimize usage

Take measurements of humidity, temperature, pressure, and other important factors to determine energy efficiency.

Perform output tests on individual compressors.

Automatically sends warning notifications to cell phones using SMS or Email using internet utilizing cloud platform.

Achieve advance automation based on specific plant demands using master controller, remote monitoring and optimization strategies for compressors as well as for dryers.


You leave yourself vulnerable to unscheduled downtime and costly emergency repairs if you fail to monitor your air compressor system.

Monitors provide timely alerts when an abnormality occurs in the system that allows you to intervene before it reaches a critical level. A monitoring system eliminates the need to keep a logbook and manually record running hours and service requirements.

No longer is it necessary to do that burdensome job. You will never have to worry about your compressor again with Compressor Services’ monitoring software and maintenance program.

Utilizing state-of-the-art technology at Turbo Airtech developed in the recent years, we can help you save money on compressed air and utility costs right away. Thanks to our advanced compressed air monitoring, you can respond in real time and prevent major failures.

We can design and implement a monitoring system that takes advantage of today’s cell phone, tablet, and computer technology (IOT) . This will provide you with convenient readings of your compressed air usage. With a few clicks of the mouse, it’s easy to access this critical data.

With modern technology, you can ensure that your compressed air system is working optimally. Regulation systems are becoming more sophisticated and new solutions are being developed at a rapid pace. Now is the perfect time to discover what your business can achieve with advanced compressed air monitoring systems.

Our advanced monitoring solutions can help you improve the efficiency of your compressed air system! Contact us today to learn more!


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