![]() Air qualityįew realize the dew point display on a refrigerated air dryer is not the “real” dew point it is just a measure of the temperature of the compressed air inside the dryer. While a bit pricey, this visual type of detection saves time and money and will be the way of the future. This approach gives a very clear picture of the location and size of leaks, something that can be difficult to determine if a leak is not readily accessible. There are now some exciting new cutting-edge leak detectors available that use complicated arrays of microphones to create an acoustical signature overlaid onto a video screen (see Figure 5). The output of this Fluke ii900 leak detector shows exactly where each leak is located. The collected data is uploaded to a cloud database for recording and tracking purposes.įigure 5. Most leak detector suppliers have developed high-end models that have onboard cameras that take pictures of each leak, record location information, and even provide some rough estimation of the leakage flow based on the decibel level. Odds are if you don’t have a leak repair program in your plant, you are running too much compressor capacity, or even running out! Being able to turn off a compressor after a leak repair is the best way to save maintenance costs and save power. There are free smartphone apps that can help you identify and record leakage locations, even storing pictures. Ultrasonic leak detectors are very valuable tools to use in reducing waste, and have become more advanced in past years, allowing you to put away your clipboard. This basic leak detector can be purchased for under $1,000 and used with a downloadable smartphone app to record and estimate leakage costs. Repair of only five cfm of leaks at present day power costs will pay the cost of a basic leak detector in less than a year (see Figure 4).įigure 4. In the past these devices have not been affordable for the average maintenance worker, but now basic units can be purchased for less than $1,000, and at this price level there is really no excuse for not having at least one detector in a plant. Leak detectorsĪnother valuable addition to any toolbox is an ultrasonic leak detector. ![]() The use of a camera can show how electrical components, compressor coolers, motors, and bearings are performing, all found with a quick glance at a thermal signature. More sophisticated, but affordable, low-cost IR cameras (see Figure 3) are available that give users a complete thermal image of operating equipment. These days Infrared (IR) detectors are very affordable and can be used in measuring and tracking critical temperatures. ![]() Very often temperature problems cause reliability challenges with air compressors and dryers. When measuring input conditions and calculating compressor efficiency (to prove your new VSD is saving money), it is important to get actual kilowatt readings and to determine the power factor so that calculations can be done correctly. ![]() An important addition to a maintenance toolbox is a good power quality meter (see Figure 2) to detect things like phase imbalances, low voltages, harmonic distortion, and conditions that may consume abnormal power. Installing one of these premium efficiency machines is an excellent way to greatly improve the efficiency of a system, but they require good quality electrical power and a clean and cool environment. Many new compressors are now being purchased with variable frequency drives to save energy. This FLIR camera is detecting abnormally high temperatures on a heated air dryer. Usually, these controls can be queried remotely by maintenance personnel on a smartphone without having to walk to the compressor room. Some premium compressors are now coming with pre-programmed web pages, and even cell modems that send data back to the OEM for analysis this information is often available to the user on a subscription basis. Where an older controller might have an “idiot light” alarm or two, the newest and most modern controllers track a wide array of internal conditions and have adjustable alerts that can be hooked to the local internet, or programmed to send text messages when conditions turn bad. More modern compressors now have sophisticated IoT (Industry 4.0) enabled electronic controls, many with digital touch screen displays, and some even tracking internal conditions over a set time span for use in local troubleshooting problems (see Figure 1). This model has wireless communications capabilities. A good power meter with capability of measuring harmonics and power factor is an essential part of a modern toolbox.
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