STEP 1
Facility review
We look at what is installed, which parameters are critical and where the losses are today.
At your facility or remote
Compressed air leak detection: the leak you cannot hear is still on the bill
A leak does not announce itself. It shows up as pressure falling further along the mains than it should, and as air consumed on a shift when nothing is running. Both are measurable, continuously.
20-30%of generated air is typically lost
per sectionpressure compared along the mains
off-shiftconsumption when nothing should run
Control points
What we measure on the air system
Compressed air is the most expensive utility on most floors, and the only one that leaks quietly for years without anyone being able to point at it.
Pressure per sectionCompared along the mains, so a drop points at the zone that leaks.
FlowActual consumption, per line and per shop floor.
Off-shift consumptionAir used while the line is stopped is a leak by definition.
Compressor run hoursLoad, unload and idle time on each machine.
Compressor powerWhat generating that air actually costs you.
Start frequencyA compressor cycling more often than it used to.
Pressure recoveryHow long the system takes to build pressure back up.
Compressor temperatureOverheating that precedes a stop.
This is not an ultrasonic survey. A technician with an ultrasonic gun finds the exact fitting that leaks; our metering tells you which section is losing air, what it costs per month, and whether the repair actually held. The two work together, and the data is what tells you when booking a survey is worth it.
A leak repaired without measurement is a leak you cannot prove you fixed
Meter the sections first, then send the technician to one zone instead of the whole plant.
How it works in practice
Situation and system response
Situation
What the system does
What you get
Pressure falls at the far end of the mains
Pressure is compared across sections and the losing zone is identified
The survey is booked for one zone, not the whole plant
Air is consumed over the weekend
Off-shift flow is recorded separately from production hours
A standing loss nobody had noticed is found
A leak is repaired
Consumption before and after is compared on the same chart
You can see whether the fix held
A compressor cycles more often than it did
Start frequency and run hours are trended per machine
Service happens before the stop
Proof
Screens from live facilities
Already running at
ArcelorMittal
Swiss Krono
steel pipe and railway wheel manufacturer
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Deployments to date are largely in Ukraine.
Rollout
From pilot to full coverage
STEP 2
Pilot on 5-10 points
A gateway, sensors and meters on the riskiest zones. Installed without stopping operations.
A few hours per facility
STEP 3
Dashboards and reports
We draw up the facility plan, set the limits for each point, the alerts and the report formats.
Shaped around your processes
STEP 4
Scaling up
The same kit across the remaining zones and facilities, with a single view for the whole company.
No new approvals needed
Next step
We will show what your air system loses in a month
Give us the layout of your mains and the number of sections. We will propose where to meter first so the losses become visible.
- CompanyPolymetrica LLC
- E-mailsales@polymetrica.net
- Websitepolymetrica.net