Know How Much Compressed Air is Leaking - and What It's Costing You - 24/7
How much is your plant losing right now?
Air Aware's AI based analysis tells you how much your system leaks, when it gets worse, and when you've fixed it.
Most plants waste 25-30% of their compressed air to leaks in the compressed air distribution system - including pipes, connectors, drops, gaskets, and old equipment. Air Aware lets you know how your facility is doing.
Air Aware also detects and counts the number of times your compressed air pressure drops below a threshold pressure value that you set. We call these sag or droop events. This issue most often occurs at a plant location somewhat distant from the air compressor.
*This example is intended to show how much this lesser-known problem may be affecting you. The numbers here are for the case in which a 100 HP air compressor delivers 480 CFM at 110 psig outlet pressure running 6-days/wk. This typical case shows the results when we have an overall 25% aggregate leakage with an electricity cost of $0.20/kWh.
Compressed Air Leakage ROI Calculator
Compressed Air Leakage
Compressed Air Loss & Impact Estimate
The Problem
Compressed air is the most expensive utility in your plant.
And it's leaking out of fittings and other places you'd never think to check!
And worse, the ACTUAL compressed air pressure at the machine doing the production work may be bouncing above and below the pressure set-point - sagging droops and surging spikes!
25%
Average Leak Rate
Of compressed air produced in a typical industrial plant escapes through leaks before reaching the point of use.
10% - 20%
Impact on Your Electricity Bill
In many facilities, compressed air generation accounts for 10% to 20% of the total electricity consumed and in some facilities it is as high as 30%!
$28K
Annual Loss - 100HP
Typical extra electricity costs from leak losses for a single 100HP compressor running two shifts.
SOURCE · U.S. DEPT. OF ENERGY · COMPRESSED AIR CHALLENGE · INDUSTRY AVG.
How Air Aware Works
- 24/7 Air Pressure and Power-Use Monitor
Web-based Data Viewing
-
Enables Closed Loop Air Leak Maintenance
-
Measure the Progress of Air Leak Repairs
-
Simplified Install - No Compressed Air Piping Mods
-
No Equipment Shutdown Required for Install
-
No Electrician, No Plumber, No IT Guru Required
-
No Guesswork - Get the Facts about Your System
-
High-Tech Behind the Scenes Makes for Easy, Reliable Data Read
-
Weekly Summary Reports Provide Easy, Big Picture Oversight
-
Your Data, Your Way! Graphs, Tables, CSV files
01
Installs in Under an Hour
Quick-connect pressure sensors attach to your existing compressed air lines without cutting pipe or shutting down your compressor. AC power current sensors clamp around existing cables and monitor air-compressor electrical power use.
02
Weekly E-mailed Reports Provide Baseline
Air Aware measures your air-pressure fluctuations and compressor power use. AI-based solutions analyze power and pressure data to calculate leakage rate in CFM, Percent of air-compressor capacity and cost in $/month. It also counts sag events in which compressed air pressure drops below a threshold value you set.
03
Alert · Analyze · Act
E-mail and SMS alerts are sent when custom-set threshold conditions are triggered. Weekly e-mail reports provide a clear, high-level overview for each connected sensor, including summary data analysis. With these facts, you can develop an appropriate action plan, track your reduction in compressed air operating costs, and validate your improved carbon footprint.
Stop paying $s to compress air only to let it leak away and do nothing useful!
Compressed Air Leaks increase your electric bill and may cause other issues, such as installing more air compressor capacity than needed. In addition, leaks can cause a drop in air pressure and an increase in set-point pressure to compensate - a costly solution. Leaks cause all components of the compressed air system to cycle more often than necessary. These additional cycles, in some cases, 30% more cycles than necessary, shorten equipment lifetime. Other indirect effects include more frequent maintenance and more frequent unexpected downtime.
Direct Consequences of Compressed Air Leakage
- More Electricity Use
- Air Pressure Sag
- Excessive Compressed Air System Cycling
Indirect Consequences of Compressed Air Leakage
- More Compressed Air Equipment Maintenance
- Reduced Lifetime of Compressed Air Equipment
- Additional Unexpected Air Compressor Downtime
- Install & Maintain Oversized Air Compressor Capacity
- Higher and More Expensive Pressure Set-Point
- Increases Carbon Footprint
Compressed air pressure sag may cause production quality issues.
Don't let compressed air pressure instability (sag) events silently and mysteriously affect production quality. With Air Aware, you can measure the compressed air pressure every second of every day at the location in your facility of most interest. Sometimes this problem is referred to as pressure instability or simply air pressure drop. With our air pressure monitoring solution Air Aware, you'll know if you have this problem and which branch of your compressed air distribution piping suffers the most from sag. Some facilities raise the compressor discharge pressure to compensate for pressure drop at production equipment during high-demand periods - a costly solution. As a general rule of thumb, every +2 psig increase in compressor set point pressure increases the cost of electricity supplying the air compressor by +1%.