The Challenge
A specialty chemicals manufacturer had a complex compressed air distribution network serving four production blocks, three utility areas, and laboratory services — extended over 20 years. Compressor energy was the plant's single largest utility expense. The plant manager estimated 15–20% losses but had no data to confirm or locate them.
A comprehensive manual audit would have required shutting down sections of the plant to measure consumption in isolation — a process taking weeks with significant production disruption. Installing a permanent sensor network had been proposed and declined twice on capital cost grounds. After three consecutive years of rising energy bills, the proposal was approved.
What Changed
47 flow and pressure sensors distributed across the network — at compressor outlets, main headers, distribution rings, and critical branch points. A full network map of consumption, pressure, and flow.
The sensor network revealed the distribution of losses within 72 hours of installation. One production block was consuming 40% of all compressed air while accounting for 25% of network capacity — the discrepancy tracing to a leaking header section bypassed for flow control but never repaired. Two utility areas showed reverse-flow events during low-demand periods from partially-open check valves.
Results
of generated air not productively used
after repair
reverse-flow eliminated
within 3 months
“A compressed air distribution network built incrementally over 20 years is not a network — it is a collection of decisions, most of them good at the time, some now obsolete. The only way to understand what a mature network is doing is to measure it at enough points to build a complete picture. A sensor network doesn't find the problems — it finds the data that lets you find the problems.”