Air Compressor System Monitoring

Many industrial systems are equipped with protection systems, but they only avoid the compressor to be destroyed in case of mechanical failure. In many cases early indication of condition decrease can be found by deploying predictive systems rather than protection systems. A good example is the CSI 6500 online prediction & protection vibration system.

Many compressor systems also have limited to no instrumentation installed. With WirelessHART essential instrumentation can be easily added for a holistic view of the compressor including optimal performance of the dryers, filters and distribution system.

• With WirelessHART instrumentation can be of great value. No junction boxes, cables or cable trays are needed.
• Compressor controls in the DCS using standard, pre-engineered libraries.
• Ultra-high-speed valves for superior anti-surge loop performance.
• Integrated operator console displays for key operations and performance data.
• On-line models to identify performance issues.
• Seamless integration in DCS or OSI PI systems for further analysis.
• Also K-NET (Machine learning) can be deployed for optimal performance against design specs.

Air compressors

Various vendors of air compressors applying Wireless Sensors to monitor the overall performance of the asset according to the OEM specifications and the end user capacity and quality requirements.

Various end users applying Wireless Sensors such as compact flow and pressure measurements in their Instrument air supply system to detect leakages and anticipate the capacity needed to adjust the compressor control.

A well know issue with air compressors is that they will not completely be monitored and often have defects at the moving parts which is not detected before a catastrophic occur. In this case often temporally diesel compressors will be used till the existing compressor is repaired.

• Case Study Rosemount DP Flow Wireless Compressed Air
• Case Study VIP Compressed Air Monitoring

• Typically between 1% and 4% reduced energy consumed by air compressors
• Energy reduction also obtained with optimum surge control
• A 10% reduction in air consumption can be obtained by deploying annubar measurement in the distribution system

• Increase the reliability, safety, and effectiveness of compressed air system
• Minimize compressor trips
• Eliminate production losses due to low air supply

Please contact Emerson Process Management for more information.