Pneumatic Fault Monitoring and Control for Sustainable Compressed Air Systems

Sustainable development in the industrial sector has been widely explored in recent years, to achieve a carbon-neutral industry. Compressed air systems are widely used in the industrial sector. Numerous energy-saving improvements have been studied within this scope, as leaks make these systems inefficient. Nevertheless, it has yet to be seen how different optimisation techniques can be utilised to mitigate fault effects. This study shows how fault monitoring was performed on a multi-actuator system, using different time domain indicators including, mean and standard deviation. This was followed by exploring the system behaviour when pressure and flowrate control strategies were executed to minimize fault impacts. Fault monitoring, using the indicator data, was successful. For instance, as a 1 mm leak was induced and the consumption increased by 34%, the standard deviation in pressure drop reduced by 6% and the mean actuation time decreased by 13%. Though the mean in pressure drop was useful for fault monitoring other pressure indicators, including standard deviation, provided additional monitoring capabilities. During this monitoring exercise, it was also found that improved sensor accuracy resulted in less reading variations, obtaining more conclusive results and identifying faults of smaller sizes. As faults were accurately identified and characterised, it was then possible to mitigate their effects via pressure and flowrate adjustments. Results proved promising, as both contributed to air consumption decreases of 16% and 11%, respectively. Although such modifications decreased the production rate by 2-5%, the previously mentioned savings outweighed this decrease. This work highlights the need for development of fault monitoring and control systems which maintain the productivity and energy performance of pneumatic systems.