Air flow meters identify leaks and reduce energy consumption

Compressed air generation can make up to 30% or more of your industrial facility's total electricity consumption. At the same time, air leaks can account for 25% of operating costs. Strategic monitoring with an air flow meter and compressed air leak detection process can reduce energy consumption, costs for compressed air and industrial gas, and free up other resources. 

Benefits of reducing your compressed air and industrial gas cost for manufacturing

• Reduce energy costs linked to compressed air and gas leaks.
• Properly allocate compressed air costs and usage to production lines or specific machines.
• Eliminate the need for extra compressor capacity through leak reduction.
• Free up maintenance team to do value-added work versus time-based maintenance checks.
• Maximize machine performance and product quality with proper compressed air or gas supply.

How air flow meters (SD flow sensor monitors) work

The SD flow sensor monitors the flow rate, volume, pressure and temperature of compressed air and specialty gases (nitrogen, argon, carbon dioxide, and helium) lines. Simply mount at zone, production line, or machine drops to quickly identify leakage and consumption values. The integrated pressure measurement assures actuators are operating at maximum efficiency and eliminates the need for a separate instrument.

Monitor industrial gases like argon, nitrogen, carbon dioxide and helium

Molten metal, found in steel manufacturing, MIG welding, etc., is susceptible to particulate contamination from the atmosphere. Shielding gases like argon and carbon dioxide are used to remove impurities and improve the quality of the final product. Nitrogen and carbon dioxide are frequently used in food and beverage manufacturing to provide an inert gas blanket on top of the product to prevent oxidation and contamination and improve the safety of the product. Helium is commonly used as a shielding gas for arc welding high heat conductivity materials such as aluminum, stainless steel, copper and magnesium alloys. Helium is also used in leak detection test systems.

The processes used to manufacture these specialty gases make them very expensive, so monitoring their use can reduce your operating costs.  

The SD family of flow meters include variants that can be configured to monitor the flow of argon, nitrogen, and carbon dioxide. Models for helium monitoring are for helium only and do not have the menu selection for these other gases.

• Check for leaks in your piping system.
• Optimize the amount of gas used.

Benefits of the SD family of flow meters

• Reduce energy costs by identifying leaks
• Reduce maintenance costs by ensuring proper operation of production equipment
• Assign accurate utility costs to business units within your plant
• Free factory calibration certificate available.

Browse speciality gases and compressed air flow meters for any application.  

Compressed air is not free

Compressed air generation can account for 30% or more of an industrial facility’s total electricity consumed. Most cost estimates reference $0.30 to $0.50 per 1000 cubic feet of air generated. 

Leaks in your compressed air system can cost you thousands of dollars every year in electricity costs. Leaks usually occur at joints, connection points and through non-operating equipment. They can cause a drop in system pressure which affects tool efficiency, equipment life and increased compressor demand. A study conducted by the US Department of Energy found that 80% of compressor upgrade recommendations do not require investment in new compressors, and instead are addressed through low cost system upgrades and an effective leak monitoring and repair program.  The estimates in the table below are widely accepted by the US DOE as well as compressed air industry specialists.