Predictive maintenance sensor to detect leakage and improve energy efficiencies

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September 2006 Sensors & Transducers

The compressed air sensor, efector Metris from IFM Electronic, continuously monitors compressed air systems to identify leakage areas and to improve energy efficiencies. Compressed air is considered to be one of the most expensive sources of energy in a plant. By identifying leakage areas in a compressed air system, the efector Metris sensor can optimise compressed air usage, improve system performance, and reduce energy costs.

Compressed air system leaks are typically found at pipe joints, couplings and connections. The efector Metris detects leakage areas by monitoring smaller areas of a plant, designated as 'zones'. A plant is divided into zones based on the number of fittings and potential leakage points in an area. When the sensor identifies a leakage area, plant personnel can pinpoint the exact leak location and repair the leak. Leak repair in compressed air systems improves the efficiency of tools and equipment, decreases system moisture, and achieves consistent system pressure.

The efector Metris sensor can be mounted in a supply pipe to monitor one machine, or mounted in a plant zone to monitor several machines. Two sensing methods are used to monitor compressed air usage. During machine operation, the sensor compares the machine's ideal air consumption to the actual air consumption. Any difference in the two readings indicates an air leak. When the machine is shut down the sensor will continue to monitor air consumption. Any measured air usage indicates an air leak.

The sensing technology of the product is based on the calorimetric flow sensing principle that ensures a constant temperature difference between two sensing elements. This method allows for greater sensitivity in air consumption, a faster response time, and a wide sensing range. Its acute sensitivity can detect small leaks, and at the same time, measure the air consumption of high-capacity compressed air systems. The compact sensor is fitted with an integrated pipe to ensure easy mounting and proper installation depth. The sensor's 4-digit numeric display provides air consumption readings and features microprocessor-based pushbutton setup.

The efector Metris has a 1,3 to 700 Nm³/h measuring range and can be locked electronically. It has a response time of less than 0,1 s, as well as analog, switching and pulse outputs for signal processing.

IFM Electronic is represented locally by Shorrock Automation.

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Predictive maintenance sensor to detect leakage and improve energy efficiencies

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