The Air Aware package includes an air pressure sensor that will measure up to 200 psia with the same components in the Watts Aware package, including all necessary software, 3 AC split-core current transformer “sensor clamps”, the NEEM-2 Data Acquisition unit, a Wireless Adapter, Wired Ethernet connection, power supplies, and necessary cables.

Lower energy costs, improve productivity, and quality with Air Aware

Compressed air systems are widely used across many types of industry due to their versatility, availability, and cost-effectiveness. But compressed air systems must be maintained to control costs and equipment performance.

The three most important and revealing applications of Sensor Synergy’s NEEM-2 Air Aware package are to

1. monitor air pressure fluctuations
2. determine the aggregate costs of leaks in the compressed air distribution system
3. track the hours and days that the compressor is running under loaded and unloaded conditions.

Monitor Air Pressure Fluctuations

Air pressure fluctuations may be measurable only at or near the machine that uses compressed air. Sometimes, different equipment in your facility may create temporary sags in the air pressure at various locations within your facility. Some of the equipment that is physically located at the most distant location from the air compressor or nearest receiver tank will be most likely to experience air pressure variations. These sags in air pressure could result in equipment producing sub-standard parts. Once this issue has been identified, there are many possible solutions, but first, you must know that these “sags” are occurring in your facility.

Determine the Aggregate Cost of Leaks

Aggregate costs of leaks in compressed air distribution systems, including pipes, connectors, air drops from header pipes along the ceiling, and receiver (storage) tanks. All compressed air distribution hardware components can leak air and waste money.

Compressed air leaks are somewhat unique in that there is no puddle of water or hydraulic fluid under the leaking connector. Also, the leaks can generally not be heard in a noisy factory and often make sounds at frequencies not within the human hearing range. Finally, it is difficult to feel air flow from the leak if you are more than a few inches away.

The NEEM-2 Air Aware can be set up to record air compressor electric power use and compressed air pressure. These measurements can be used to determine the effective aggregate leakage of the system in CFM and in percent of the air compressor system that is wasted due to “filling leaks”.

According to the US Department of Energy guidance, a truly well-maintained compressed air distribution system may leak about 10% of its output. A more common finding was that 25% to 50% of the air compressor output was lost to filling leaks.

In some prior deployments, we have found that this can translate into substantial financial losses, in the range of $50,000 to $150,000, due to additional electricity costs. 

The NEEM-2 Air Aware will not find individual leaks. It will indicate how much air is being lost to leaks and when it is time to hire the air compressor people to fix the leaks. In before-and-after measurements, the Air Aware will also indicate how effective the leak repair efforts were.

Track Compressor Runtime

Tracking the loaded and unloaded hours of compressor operations is essential in determining how hard your compressor is working and whether or not you might need another air compressor to handle the load. It should also be noted that excessive compressed air leaks in your facility’s compressed air distribution piping/connectors can cause your compressor to work harder than it needs to work. Eliminating many of the larger compressed air leaks can eliminate the need to purchase and install another air compressor.

Custom Sensor Packages

The NEEM-2 is a powerful tool that can be modified to accommodate many types of 2-terminal sensors. Contact us for a free 45-minute discussion about your specific remote monitoring need. We may be able to propose a custom solution with the appropriate sensor for your situation.

Ready to Install 

The NEEM-2 is intended to be a Do It Yourself (DIY) installation and setup of a remote monitoring system. Basic skills found in most manufacturing facilities will be needed to set up the NEEM-2 at your facility.

Contact Sensor Synergy’s technical support at
224-436-4132