Measurement technology

Measuring systems and methods

Startseite Product segments Measurement technology

High benefit due to low investment

Compressed air fulfils important tasks in the process industry. However, the life-cycle costs of compressed air generation – above all the ongoing energy costs – are a major factor. Many operators are often unaware of how expensive compressed air really is, because 25 – 40 percent of the compressed air generated is lost through leakage. If a system is switched off, no compressed air should be consumed. If this is nevertheless the case, it is a clear indication of leakage.

OIL CHECK 500 – Monitoring System

HIGH-PRECISION MEASUREMENT OF THE VAPOROUS RESIDUAL OIL CONTENT IN THE COMPRESSED AIR

Innovative “Forced Pressure Variation” for long-term stable measurement results and easy auto-calibration. Thanks to the measuring method developed by CS INSTRUMTENTS, the device internally generates reference gas in various mass concentrations in order to effectively compensate for ageing or contamination-related influences in the measurement signal, in particular long-term drift. In contrast to conventional methods, the OIL CHECK 500 does not require any wearing parts such as activated carbon filters for zero air generation, which results in a low-maintenance and permanently stable measurement.

Our solution

OIL CHECK 500 – for highly accurate measurement

The new device is not only easy to service, but also minimizes downtime. The pre-calibrated sensor unit makes it easy for the customer to replace it on site, eliminating the need to send the entire device back for recalibration.

FOR MAXIMUM PROCESS RELIABILITY

The OIL CHECK 500 monitors all functions and components internally. The service software can be used to create comprehensive function test reports to ensure that the device is always working perfectly.

ON-SITE CALIBRATION

Thanks to the on-site calibration option with test gas cylinders, the OIL CHECK 500 offers flexibility for mobile measurement. The service software enables the creation of verification and calibration reports (as-found data and as-left data) to ensure that measurements always meet the highest quality standards.

COMPACT DESIGN

Thanks to its compact design, paired with easy sampling, the OIL CHECK 500 is the ideal solution for fast and precise measurements in various environments.

OIL CHECK 500 – your reliable result without great effort

Flyer OIL CHECK 500

The new FO 510 – oil moisture sensor

INLINE MOISTURE MEASUREMENT IN OIL: INCREASE IN QUALITY AND EFFICIENCY

Accurate determination of moisture in oil is crucial to ensure quality and efficiency in various industrial applications. CS Instruments’ measurement solutions enable you to optimize operational processes, prevent failures and maintain the highest quality standards. Rely on FILCOM GmbH’s expertise in moisture measurement to improve your industrial processes.

Our solution

FO 510 – OIL MOISTURE SENSOR

The FO 510, developed by CS Instruments, is an extremely precise and stable sensor, specifically designed for the precise measurement of water activity (aw) and oil temperature (t) in lubricating, hydraulic and transformer oil as well as diesel fuel. The recorded data is transmitted via two 4-20 mA outputs and the Modbus RTU interface. The optional service software allows the user to additionally customize the oil sensor, make Modbus settings and determine the initial configuration.

SPECIAL FEATURES

  • Measured variables: water activity (aw), temperature (t) and water content in ppm (x) (possible for transformer oils)
  • Fast reaction time
  • Can operate up to 100 °C oil temperature
  • Pressure-resistant up to 300 bar
  • Zwei analoge Ausgänge
  • Digital Modbus RTU interface
  • ISO G1/2″ or 1/2″ NPT thread connection

AREAS OF APPLICATION OF THE SENSOR

  • Transformers oil
  • Motor oil
  • Lubricating Oil
  • Hydraulic oil
  • Diesel fuels
Technical data sheet FO 510 oil moisture sensor Operating instructions FO 510 oil moisture sensor

The new KAESER measuring technology – KM series

Effective immediately, KAESER has added intelligent process data acquisition to its product range with the KM series. Intelligent sensors monitor the entire compressed air system and can bundle data, analyze it and make it usable. If irregularities occur in the system, they can be quickly detected and corrected. The KAESER compressed air management system SIGAM AIR MANAGER 4.0 enables central monitoring and provides key figures. This makes it easy to analyze and visualize data. Likewise, exceeding and falling below limit values are reported immediately. Defined parameters and KPIs can be displayed by condition monitoring, thus tracking the operating conditions for all installed components. Thanks to the new measurement technology, the compressed air supply is always in focus and targeted optimization of energy use can take place.

NEW ACCESSORIES

  • In the future, a plug-in power supply, a connection box for up to two measuring devices and a pre-assembled signal cable can also be selected.
The invisible becomes visible

KAESER KM series – Intelligent process data acquisition

THE ADVANTAGES AT A GLANCE

  • Multiple data acquisition
  • Consider all relevant measured values per measuring point
  • Power of Ethernet (PoE)
  • Easy data integration via SIGMA NETWORK

PROCESS DATA ACQUISITION

  • Real-time monitoring
  • Data evaluation, key figure formation, monitoring, troubleshooting
  • Understanding and evaluating interrelationships
  • Monitor and screen the system

THE COMPRESSED AIR SYSTEM

  • Uniform, high-quality sensor technology
  • Simple installation and commissioning
  • Certified products

CUSTOMER BENEFITS

  • Energy saving potentials become transparent and can be implemented in a targeted manner
  • The exact determination of the actual conditions leads to the full exploitation of energy saving potentials
  • Ensuring participation in KAESER further developments in hardware and software
Brochure “KAESER Measurement Technology”

CS Instruments Measuring systems

The topic of energy saving is very important for companies from many industries. Innovative measurement technology for compressed air and gases from CS instruments offers the right solution here. The product portfolioof the most diverse measurement technology ensures the provision of usage statistics or the monitoring of a compressed air system. Standard-compliant methods for the metrological detection of impurities in compressed air can be implemented through a large portfolio of different measuring systems. This ensures energy savings and safety in production.

The pillars of compressed air quality measurement according to ISO 85731

Dew point measurement according to ISO 8573-3

  • Measurement of the pressure dew point immediately after compressed air preparation or in the compressed air network acording to ISO 8573-3
  • Pressure dew point measurement is carried out on site, evaluated and documented
  • Pressure dew point measurement from -80 °C to +50 °C
  • Prerequisite at the measuring point: Quick coupling, measuring point free of liquid condensate
  • Measurement is carried out with calibrated electronic measuring instruments that are subjected to annual calibration

Hydrocarbon according to ISO 8473-2 and 8573-5

  • Hydrocarbons transported by compressors (oil-free and oil-cooled) – in the form of liquids, aerosols or steam – enter compressed air lines
  • The origin of the contamination is, for example, improperly maintained compressed air generators or concentrated oil-like hydrocarbons from the environment.
  • Other sources of contamination can be piping systems or compressed air reservoirs
  • Hydrocarbons show up in compressed air systems as aerosol or vapour impurities in the compressed air
  • Standard-compliant determination of aerosol and vapour content for the determination of the total hydrocarbon content and thus the classification of the compressed air quality class
  • Standardised sampling fitting for isokinetic sampling
  • Analysis of the samples taken – both for the hydrocarbon aerosol and for the vapour content – is carried out by an accredited laboratory
  • Individual evaluation of the vapour sample enables identification of all hydrocarbons contained in the sample

Particle measurement according to ISO 8573-4

  • The origin of particles in compressed air is usually in the ambient air drawn in by the compressor and the dust it contains.
  • Particles can also originate from abrasion or residues and corrosion products from the compressed air system
  • When mesuring particles of media from the pressure lines, the selection of the sampling location, the method of pressure relief and the selection of the specific measuring technique are decisive in particular
  • Particle measurement is strictly oriented to the descriptive standard ISO 8573-4 with regard to measurement methods, equipment and documentation.
  • The compressed air is taken in a completely relaxed state and fed to the particle counter without affecting the particle spectrum.

Leakage management

Use our leak detection service and quickly reduce your compressed air costs. You will increase your process reliability.

COMPRESSED AIR LEAKAGE MANAGEMENT BY FILCOM

  • We locate the compressed air leaks along the entire compressed air chain with our leak detector LD 500 from CS Instruments during operation
  • All located leaks are marked and documented
  • We evaluate every compressed air leak economically and ecologically
  • Following the detection, your receive documentation of all detected leaks, including compressed air consumption, energy costs and CO2 emissions
  • Upon request, compressed air leaks can be professionally repaird by FILCOM
  • If you would like to carry out the leakage repair yourself, we will supply you with all spare parts with clear allocation to the respective leakage
Looking for leaks is worthwhile!

Your added value

  • Quick and easy determination of your leakage as well as the savings potential
  • Smallest leakage detectable even at great distances
  • Image documentation of your leaks
  • Paperless documentation through on-site entry in the unit: definition of the location of the leakage, corresponding remedial measures and spare parts
  • Creation of a report according to ISO 50001
  • Multi-user capable due to Cloud Solution

Learn more

EXAMPLE CALCULATION FOR A MEDIUM-SIZED COMPANY

Approx. 25 % of the compressed air is lost due to leakage

Installed compressor capacity 150 kW (el) x 6,000 Bh x 0.12 € / kWh

Annual electricity costs 180,000 €

25 % leakage costs: € 27,000 per year!

Measuring compressed air consumption

CONSUMPTION MEASUREMENT = ENERGY SAVING

Consumption measurement is useful to show the efficiency and economy of a compressed air station based on the running behaviour. The compressed air consumption is recorded by means of a data logger. This is connected to the systems to be measured and records the consumption of your compressed air station over a specified period of time. The subsequent compressed air consumption diagram shows any fluctuations in consumption, the load and idling behaviour as well as the allocation of the power of each individual compressor to the respective compressed air consumption.

With plan for visualising your compressed air consumption

Whether plant optimisation or customised new planning: at FILCOM, customers benefit from the consulting and planning expertise of a well-positioned team for products from the largest compressed air system supplier for compressors and blowers – KAESER Kompressoren SE. With versatile analysis methods from a wide range of manufacturers and an experienced and trained feel for the requirements of a wide range of industries, the FILCOM team offers its customers future-proof solutions, precisely in line with the required demand, which save money and are also good for the environment.

Types

Step 1

WE UNDERSTAND YOUR REQUIREMENTS

Your new compressed air station must be as individual as your requirements as an operator. That’s why we listen and look very closely and ask the right questions. Our diverse industry knowledge help us to do this – regardless of whether you manufacture jewellery or semiconductors, operate a cement plant, a car factory or a brewery. Together with you, we record all the necessary production parameters and framework conditions. This includes, for example:

  • Air quality
  • existing components
  • Installation site

Step 4

THE INDIVIDUAL COMPRESSED AIR STATION

Based on our evaluation, the FILCOM team will map out a way for you to significantly increase the efficiency of your compressed air station and maintain it for the future. You will benefit in the long term through savings that can only be achieved by taking a system approach. Thanks to the use of state-of-the-art compressor management from KAESER Kompressoren SE, electricity and compressed air costs are transparent and your reliability is always in view thanks to browser access. The control sytem also actively sends an energy report when required.

Step 2

ANALYSIS OF COMPRESSED AIR UTILISATION

The analysis is the core. Here, we use a wide variety of measurement technology that is needs-oriented, customer-specificand independent of manufacturers, depending only on the application. Sometimes the combination of different measuring systems makes the difference to success.

  • Flow measurement air
  • Current consumption
  • Temperatures
  • Ultrasonic measurements
  • Speed measurements

In most cases, it is necessary to record several sensors and evaluate them later. In this way, we identify weak points and uncover unused potential, which we then present to you in a personal meeting.

Pdf-File Download

Step 5

COMMISSIONING & MAINTENANCE

After successful commissioning, we take over the maintenance of your systems and thus ensure a highly efficient compressed air station throughout its entire service life.

With our comprehensive stock of spare parts and rental machinery, combined with our emergency service, short response times are guaranteed.

Step 3

THE EVALUATION OF THE DATA OBTAINED

For this purpose, we use the most modern evaluation software to guarantee high quality data. In order to obtain an economic solution that works close to the optimum under all conditions, several concepts must be compared. The gradiations between several compressors must be considered just as much as the entire downstream processing. The pressure losses up to the last consumer are significantly relevant.

Individual solutions

WE OFFER OPTIMAL SOLUTIONS

Because we believe that solutions are only as good as the preparation. We adapt your compressed air systems to the respective production conditions, the place of use and your specific needs. No matter whether you want to optimise your system or are planning a new one. The FILCOM team accepts the challenge. Because we are optimally equipped to find the right solution for every customer.

Contact

Do you need a consumption measurement or have any questions? Please feel free to contact us!

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