Key points
TL;DR Summary Box
Inline flow sensors in process industries help reduce energy waste, lower operational costs, and support productivity. They detect inefficiencies in compressed air, nitrogen, and liquid systems, provide real-time data for predictive maintenance and energy management, and enable compliance with ISO 50001 energy standards. Flow sensors allow operators to manage low flow rates, optimise gas and liquid use, and make data-driven decisions to control costs and improve sustainability.
Pratik Vishwakarma, Product Manager Industrial Automation, IMI, says the specification of inline flow sensors within process environments can help mitigate the potential for energy waste, lower cumulative energy costs and support productivity goals.
Government Initiatives and the Push for Energy Efficiency
The recently announced government 10-year industrial strategy includes proposed measures to tackle the prevailing high cost of energy experienced by the UK’s industrial sector.
The measures, which could slash energy bills by up to 25% for more than 7,000 UK businesses, were unveiled alongside other plans aimed at boosting economic growth. A new British Industrial Competitiveness Scheme will cut costs by up to £40 per megawatt-hour from 2027 for more than 7,000 manufacturing firms by exempting them from certain extra charges that currently support sustainable energy and back-up power supply systems.
However, despite this welcome development, many companies, especially in the process sector, continue to grapple with the impact of energy consumption and search for ways to be more energy aware and efficient.
The Energy Impact of Compressed Air and Gas Systems
For typical process industries such as water and food and beverage, a reliance upon compressed air and nitrogen systems can silently drain operational budgets especially if accurate visibility on system performance is not in place.
Hard working actuators, and pneumatic controls are energy dependent, yet avoidable system inefficiencies such as leaks, over-pressurisation, or undetected usage, routinely make these systems significant energy consumers.
In fact, the energy impact for compressing air can account for over 30% of a process plant’s electricity usage, with typical installations costing £40,000/year for a 500 L/s system.
Despite this, leaks often go unnoticed or undetected with many systems loosing up to 30% of their generated air before it's even used. These hidden inefficiencies directly inflate energy bills, drive higher COâ‚‚ emissions, and undermine sustainability targets.
Understanding Inline Flow Sensors
However, in recent years, developments in advanced inline flow sensors have seen them emerge as an essential tool to combat the potential impact of unwanted inefficiencies. And the specification of flow sensors across a multitude of applications is delivering operational and financial benefit.
For instance, using a flow sensor can optimise and manage liquid flow to enable essential data acquisition that can alert safety alarms, help diagnose a potential process issue and support the analysis and implementation of remedial actions if required.
The flow sensor also allows for management of low flow rates as seen with equipment discharge and spray volumes, alongside the effective management of air, nitrogen, or argon gas supplies based on instantaneous and total flow rates. The insight provided by the sensor technology allows for more informed decision making that can drive improved outcomes.
Key Benefits of Inline Flow Sensors
- Instant detection of inefficiencies
With system downtime both costly and inconvenient, using flow sensors as part of the flow control oversight enables process operators to drive both predictive maintenance strategies and superior device protection.
Immediate detection of a decrease in flow rate makes it possible to perform a required maintenance action without delay and avoid adverse effects on production or equipment. - Providing the data to build an energy management strategy
The installation of inline flow sensors can also be a positive contributory component to adhere to recognised standard compliance.
ISO 50001 is the International Organisation for Standardisation’s (ISO) energy management systems specifications and ISO 50001 Energy Management Standard defines best practices and how the use of thermal flow sensors/meters can highlight gas flow rates to comply with recommended practices.
And the newly disseminated ISO 50001 standard now further defines the best practices for energy management. It advocates that flow sensor-based monitoring with thermal mass flow meters can play a significant role in the delivery of energy management performance and optimised energy use.
The IMI Norgren M/80 series of inline flow sensors are designed to help process operators develop energy management strategies by producing the level of detailed data that aligns with the ISO 50001 standard. - Cost Control
As well as being an essential tool in the fight to help identify and rectify areas of energy waste in commonly used compressed air systems, inline flow sensors can be extended into additional processing areas.
For instance, many manufacturing sites will opt to use argon gas for welding, nitrogen gas for oxidation-prevention and heat treatment, as well various other resources such as hydraulic oil and coolant.
As with other areas of processing operation, including a high performing and effective flow sensor as part of the overall flow control system enables production teams to additionally visualise the levels of resources being consumed. This can be the basis for onward analysis, as well as providing a data-led platform on which to build future operational decisions aimed at better controlling energy costs.
FAQs
What is the purpose of inline flow sensors in industrial processes
Inline flow sensors monitor the flow of gases and liquids to detect inefficiencies, prevent energy waste, and optimise operational performance
How can flow sensors reduce energy costs
They detect leaks, over-pressurisation, and underused resources, enabling corrective actions that lower electricity and gas consumption
Which industries benefit most from inline flow sensors
Water treatment, food and beverage, manufacturing, and other process industries that rely on compressed air, nitrogen, or liquid systems
How do flow sensors support energy management standards
Flow sensors provide detailed data that aligns with ISO 50001, helping companies monitor and optimise energy use according to best practices
Can flow sensors be used for gases like nitrogen and argon
Yes, they can monitor the flow rates of nitrogen, argon, and other gases used in welding, oxidation prevention, and heat treatment
Do flow sensors assist with predictive maintenance
Yes, they provide real-time data on flow rates, allowing maintenance teams to act before downtime or equipment damage occurs
How do flow sensors contribute to sustainability goals
By reducing wasted energy, detecting leaks, and optimising resource use, flow sensors lower COâ‚‚ emissions and support environmental targets
What types of resources can be monitored with flow sensors
Compressed air, nitrogen, argon, hydraulic oil, coolant, and other liquids or gases used in process operations
How do flow sensors help in decision-making
They provide actionable data for production, maintenance, and energy management, enabling informed operational decisions and cost control
