v3
Compressed air monitoring
Follow pressure and compressor runtime through production and idle hours. Use the readings to guide leak investigations and check the effect of repairs.
Operations and maintenance can work from the same pressure and runtime record. Compare the hours when air is needed with periods expected to be idle before choosing where to investigate.
Follow pressure after production
v3-4Watch pressure during production and an agreed idle check with the compressor off. Falling pressure prompts an investigation of air loss.
An alert prompts a pressure check
- Production running
- Idle check: compressor off
- Pressure threshold
During the agreed idle check, the compressor is off and the pressure trace shows whether the system loses pressure. Maintenance uses that change to guide investigation of the air loss.
The dashboard combines the pressure, runtime and flow readings selected for the system. A recorded baseline and reports help you compare operation after repairs, with continued support from our team.
A missing-reading alert prompts checks of sensor power and its wireless connection.
Explore the compressed-air dashboardHow pressure alerts work
Monitoring put to work
Process adjustments and off-shift leak investigations use different combinations of readings. These cases show how the measurements directed the next operating check.
PDI: process changes from the readings
PDI Bulk
The dashboard showed where water and compressed air were used. The facility made process adjustments based on those readings.
$150,000per year
Jeff Inkes, general manager, reported more than $150,000 in annualized cost reductions across water and compressed air together.
Find air use while production is idle
A Tier 2 automotive stamping factory
Pressure, compressor load and off-shift flow revealed continuing air use. The readings guided a leak-repair list and checks after the work.
Read pressure, runtime and flow together
v3-3Compressed air monitoring starts with the operating question you need to answer. We select metering points that help you examine that question.
| Reading | What it tells you |
|---|---|
| Header pressure | Pressure through production and agreed idle checks. |
| Compressor current | Compressor operation and runtime, alongside pressure. |
| Flow monitoring | Air use in the areas that need a separate reading. |
Compressor current follows operation and runtime; a separate flow reading measures air use at its monitoring point. Read pressure alongside those signals when checking cycling or continued demand after production.
We check existing instruments for compatible pulse, 4-20 mA or Modbus outputs. A power-based alert uses an appropriate power reading.
Wireless sensors send readings through 900 MHz radios, including Digi XBee, to a site gateway and your centralized dashboard. We check gateway power and the wireless path during the visit.
The gateway can use a separate cellular connection and store readings locally during an internet interruption. We confirm the connection with you.
Give each air alert a first check
v3-5We configure phone and email alerts around the conditions you choose. Set the recipients and timing with us before monitoring begins.
Header pressure falls
- Trigger
- Pressure remains below its threshold for the selected time.
- Notify
- The maintenance contact responsible for compressed air.
- First check
- Check compressor operation and current air demand.
The compressor runs during idle hours
- Trigger
- Monitored compressor power exceeds its threshold during selected idle hours.
- Notify
- Operations and maintenance contacts.
- First check
- Confirm which air users should run, then compare runtime and pressure.
Plan the monitoring together
v3-1- 01
Walk the facility with us and choose the operating question to investigate.
- 02
We check the monitoring points and plan access and installation around your schedule.
- 03
We connect the instruments, check the first readings and continue supporting the monitoring.
Include someone who knows compressor schedules and can arrange an idle check. Bring pressure, current and flow instrument details where available.
After connection, we work through the baseline and the operating hours with you. The record then provides a reference for following pressure and runtime after adjustments or repairs.
Useful next steps
v3-6Funding depends on location and project scope. We help define measurements and assist with paperwork alongside your team.
Save on Energy: Retrofit Program
For electricity-saving compressed-air equipment or control upgrades.
BC Hydro: Self-serve incentives (lighting and compressed air systems)
Check system assessment and pre-approval requirements for compressed-air projects.
Air measurements
Compare readings for the air system.
Watch the dashboard walkthrough
The walkthrough includes dashboard views and air-compressor examples. Use it to see how the readings fit together before discussing the monitoring points for your own system.
Before you book
Can existing instruments connect?
We check each instrument output and configuration. Pulse, 4-20 mA and Modbus provide compatible connection options.
How does monitoring help find leaks?
Pressure, runtime and selected flow readings narrow the investigation. Continuing readings show what changes after repairs.
How is installation planned?
Access to the header, compressor and instruments determines the work. Any idle pressure check is arranged with operations.
Who receives a pressure alert?
You choose the recipients and notification channels. We set the threshold and timing with you before configuration.
See what keeps the compressor running
Show us the compressor schedule and the air use you want to investigate. We will choose the pressure, runtime and flow readings together.
or call 1-833-QUANTFY (1-833-782-6839)