Tips for Optimizing Compressed Air Systems

There are a number of ways to maximize and optimize compressed air systems for increased air efficiency. Listed below are some items that you can do to save plant facility costs.

It is advised that one must take compressed air system training as a first move in optimizing your system. This can assist in fully understanding available equipment and how it operates. Having knowledge on how compressor units run gets facility costs in line as inefficient units are replaced, maintenance procedures are changed and low costs measures to reduce system wastes are performed.

Handling compressed air system costs entails measuring your system. To be familiar with the challenges involved in improving your system’s efficiency, air quality & stability, and reliability, it is essential to set a baseline. Monitoring a system requires measurement of key parameters including pressure, flow, power, and dew point over a given amount of time. Collected data must be analyzed to detect issues and used to improve current system.

Instigate Efficient Compressor and Dryer Control
Controls of air compressors as well as associated equipment such as air dryers are vital to your system’s efficiency and reliability. A range of control systems of varying complexity are available and can be set up in compressed air systems to help synchronize operation of compressors. Coordinating operation includes securing right compressors are running at any given time, that unit is functioning efficiently, and that system pressure is maintained within limits.

Oftentimes, an air dryer control is not given importance on system management efforts, especially where desiccant style dryers are used. Dewpoint controls lessen desiccant dryer purge demand if dryers are undergoing flows less than rated conditions. Energy costs for non-cycling refrigerated dryers can be trimmed down by ensuring any spare dryers are turned off when associated compressors are not functioning.

Improve Unit Efficiency by Replacement
A costly major overhaul on old air compressors may not be advisable as old equipment may not be up to present day standards. Instead of repairing old and ineffective compressor or compressor motors, it may be ideal to look for more efficient equipment replacements. Replacements can decrease operating costs going forward and cover for replacement costs in a short run. The Compressed Air and Gas Institute (CAGI) data sheets can be used to compare various options when selecting what model of new compressors to purchase and computing for operating costs savings.

Install Storage Receivers
Storage receivers can raise overall system efficiency by helping compressors ride out passing high flow compressed air demands that might start another compressor unnecessarily or might require compressor to operate inefficiently in unloaded mode, both increasing power costs. Storage receivers that are protected by valves can be installed on production machinery being affected by localized pressure fluctuations to guard against short term transient low pressure events.

Lower the Compressed Air Pressure
Understanding actual pressure requirements and comprehending that supplying extra pressure leads to unnecessary compressor power consumption are keys to optimizing your system. If there is no good reason for high pressure, then it must be lowered.

Improve Effectiveness of Air Treatment
Compressed air treatment units can be a major source of energy loss through purge loss for desiccant dryers, refrigerated dryers electrical power consumption, pressure loss, or through extreme drainage. As good efficiency measures, it is best to use air dryers that apply less power, low- or no- purge flow, and/or lower designed pressure differential. Psi reduction in pressure differential or lowered cfm of wasted compressed air means there is less energy being consumed at the air compressors.

Develop Plant Piping
Underdeveloped compressed air piping can cause flow restriction in compressed air systems, forcing compressor discharge pressures higher to compensate. Compressed air piping pressure differential must be measured to determine any issue that might impede the system optimization process. A good system should have 10% or below pressure differential throughout the complete system from the compressor room to the end use piping drop.

Lower Component Pressure Loss
A key item to monitor is the amount of pressure differential available between the piping drop and the actual end use of the compressed air. Occurance of major pressure differentials leads the discharge pressures at the air compressor end of the system to rise and compensate, increasing power costs. Giving attention to sizing these components for low pressure differential at peak flows can save compressor costs.

Employ Leakage Detection and Repair
Repairing compressed air leaks is one of the simplest ways to achieve energy savings in a compressed air system. Usage of tools like ultrasonic leak detection instruments on regular maintenance programs can help get better results. A leak level of 10% of the average compressed air flow is a good level to strive for. Reduction in leakage flow decreases power required by air compressors.

Lessen or Eliminate Inappropriate Uses
Inappropriate usage of compressed air must be identified and analyzed during air system study. There are a number of compressed air powered activities including blowing, cooling, pumping, and atomization of fluids that can be achieved more efficiently using other sources of energy. Air system studies compares life cycle costs of doing the same job using different methods. There are some cases where use might not be completely discarded but can still be optimized by distributing lower pressure, turning off the use when not demanded, or redesigning it to operate with less compressed air.

Achieve maximum energy efficiency by following the listed items above and by using dependable as well as heavy duty compressors. Worthington offers a wide range of high quality rebuilt compressors that can keep your plant facilities running continuously and smoothly. Browse our extensive selection by visiting http://www.worthingtoncompressor.com/rebuilt-compressors-on-sale today!