Compressed Air Audit Instruments

A compressed air audit is only as good as its measurements. Nameplate ratings and running hours give an estimate; temporary instruments installed during normal production show what the system actually does. WiseAir makes the sensors and loggers that energy auditors, consultants and plant engineering teams use to build that measured baseline.

This page lists what each measurement tells you during an audit and which WiseAir instrument does the job.

What to measure in a compressed air audit

• Flow shows actual air demand by shift, leakage during non-production hours and how demand changes with production.
• Pressure at the compressor outlet and at key users shows pressure drop across dryers, filters and pipework, and whether generation pressure is set higher than the plant needs.
• Power on each compressor gives load and unload behaviour and, together with flow, the specific power (kW per CFM or kW per m³/min) of the compressor room.
• Dew point after the dryers shows whether the air quality matches what the process needs and whether dryers are overloaded.
• Leaks found with an ultrasonic detector or acoustic imager are tagged and quantified so the repair list can be ranked.

Flow sensors for audits

For temporary audit work, insertion sensors are usually the practical choice because they go into an existing pipe through a ball valve without cutting the line.

• WAFS 104 insertion thermal mass flow sensor: the common choice for main headers and compressor outlets.
• WAFS 106 insertion thermal mass flow meter.
• WAFS 103 pitot tube flow sensor and the WAFS 103D bi-directional version for ring mains where flow can reverse.
• Inline sensors such as the WAFS 105 and WAFS 107 suit permanent measurement on smaller lines and machine branches.

See all options on the compressed air flow meter page.

Pressure, power and dew point

• WAPS 501 pressure sensor for logging pressure at the compressor room and at the far end of the network.
• WAPM 401 hand held power meter for temporary clamp-on measurement on each compressor, and the WAPM 402 panel mounted meter for permanent installation.
• WADS 207 / 208 portable dew point meter for spot checks after each dryer, and fixed WADS 201 dew point transmitters for continuous logging.

Leak detection instruments

• Ultrasonic leak detectors and the WA-EUS-740 for walk-through leak surveys.
• The WA-EUS-750 acoustic leak imager shows leaks on screen and estimates their size, which makes the repair list faster to build and easier to verify after repair.

Use the leak cost calculator to put a yearly cost on the leaks you find.

Logging the data

All WiseAir sensors can log to the WASM 604 monitoring software, so flow, pressure, power and dew point are recorded on one time base. That makes it straightforward to calculate specific power, leakage percentage and pressure drop for the audit report, and to keep the sensors in place afterwards for continuous monitoring.

Calibration

Audit results depend on instrument accuracy. WiseAir offers calibration services for its flow, pressure and dew point sensors.

Need the audit done for you?

WiseAir supplies the instruments. If you want a compressed air energy audit carried out for your plant, it is delivered by our group company Systel Energy Solutions as part of its compressed air digitization service. See how the Systel compressed air energy audit works.

Buy or ask about audit instruments

Tell us the pipe sizes, line pressure and what you need to measure, and we will recommend the right sensors.

Email: info@wiseair.in | Phone: (+91) 90477 78715 / (+91) 98944 49015