Reference · built on requestOperator by FibricProduction & maintenance

Air Leak

Reads compressor load and air flow during idle periods and proposes a leak survey work order with the zones to check first.

Request accessPricing ↗

About

Air Leak is an operator for compressed air that escapes while nothing is running. The US Department of Energy's compressed air tip sheet says leaks often waste as much as 20 to 30 percent of a compressor's output, and lists couplings, hoses, fittings, quick disconnects, FRLs, condensate traps, and valves as the common places.

This operator reads compressor load over Modbus TCP, flow and pressure from meters or from Monnit and Milesight sensors, and the production calendar. During idle periods it compares load and flow with the baseline you approved and, when they rise, proposes a leak survey work order in your CMMS with the zones ordered by where pressure fell fastest.

This is a reference listing. It documents what Fibric would read from Air Leak and what it could propose, based on the vendor's published interfaces. Fibric builds it under a managed deployment when you request it; selecting it here installs nothing.

Inputs

  • Compressor load from the drive or compressor controller over Modbus TCP: kW, current, run hours, and load or unload state from the registers you map
  • Air flow and header pressure from meters read over Modbus TCP, or from Monnit pressure and air velocity sensors reporting on their heartbeat
  • Zone valve state or branch pressure from Milesight devices, read as DEVICE_DATA events or property history
  • Production state: a shift calendar in a sheet, or a running tag from the line, that says when the plant should be idle
  • Leak work orders already open in Fiix, MaintainX, or Limble CMMS, and the zones they cover
  • Time-series history kept in ThingsBoard, read with MIN, MAX, and AVG aggregation over an idle window

Proposed actions

  • Target capability: propose a leak survey work order in your CMMS when idle-period load or flow rises above baseline, naming the zones to check first
  • Target capability: propose the survey's zone order from which branch pressures fell while valves were closed, so the largest leaks are checked first
  • Target capability: propose a Fiix or MaintainX meter reading of the idle-period flow, so leak load is tracked against the compressor asset
  • Target capability: propose a follow-up work order to re-measure idle flow after the repairs are logged, as the tip sheet's verification step

Proposed actions are target capabilities. Every action runs propose-first and needs a validated deployment and the appropriate permissions.

What you can build

  • Baseline idle load from the compressor drive

    kW and load state are read over Modbus TCP every idle window. When the idle load climbs past the baseline you approved, the operator proposes a Fiix work order for a leak survey with the trend attached.

    With Modbus TCP, Fiix

  • Rank zones by branch pressure decay

    Milesight pressure devices on each branch report while zone valves are closed. Branches that lose pressure fastest go first on the proposed MaintainX work order's zone list.

    With Milesight Development Platform, MaintainX

  • Re-measure after repairs in Limble

    Monnit air velocity readings during idle hours are compared before and after the repairs are logged. The operator proposes a Limble task for the re-measurement, so the before-and-after values sit against the compressor asset.

    With Monnit iMonnit, Limble CMMS

  • Use ThingsBoard history for the window

    Telemetry already in ThingsBoard is read with MIN and AVG over each idle window. The operator proposes the survey work order in Fiix when the idle minimum rises across several nights.

    With ThingsBoard, Fiix

Requirements

  • Compressor load over Modbus TCP: a register map for the drive or controller, with kW or current and the load state
  • A flow or pressure measurement on the header or main branches: a Modbus meter, or Monnit pressure and air velocity sensors
  • A production calendar or a running tag that marks idle periods
  • A CMMS for the survey work order: Fiix, MaintainX, or Limble CMMS
Authentication
Registers, sensor messages, and work orders pass through the Modbus, sensor, and CMMS connectors you bind and the credentials each keeps; the operator signs in nowhere.

Limits

  • It infers leaks from load and flow while the plant is idle. Equipment left running through that window reads as leakage until you exclude it
  • Zones are only as fine as your sensors. Without branch pressures, the proposal names the header, not the fitting
  • It does not find or fix leaks. The DOE tip sheet names an ultrasonic acoustic detector as the best detection method, used on the survey
  • Modbus TCP reads follow the polling schedule you define, so a short idle window needs a poll rate to match

Access and pricing

Reference listing. Fibric builds the operator under a managed deployment when you request it. Your quote covers the build, capabilities, usage, and support.

Request Air Leak ↗

Questions and answers

What does the maintenance lead approve?
The survey work order: the idle window, the load and flow readings behind the call, the baseline, and the ordered list of zones. You approve it, reorder the zones, or dismiss it. The follow-up re-measurement is a second proposal after repairs are logged.
What trail does it leave?
The registers and sensor messages read, the idle windows used, the baseline, the work order as the CMMS created it, who approved it and when, and how to cancel it. A later re-measurement is linked to the survey it closes.
Does it control the compressor or the valves?
No. It reads load, flow, and pressure. It never writes a register, changes a setpoint, or operates a zone valve. Its only writes are work orders and meter readings in your CMMS, each after approval.
Ask about Air Leak

Ask about the capabilities and requirements in this listing.

For project-specific requirements, contact Fibric.

This operator is developed, published, and supported by Fibric. Third-party names and logos identify the systems an integration connects to; they are the property of their respective owners, who are not affiliated with Fibric and do not sponsor or endorse this listing. Trademark policy