How to Optimize Your Compressed Air System (Part II)
In our previous post, we have discussed with you the importance of optimizing your compressed air system. We have also given you three of our top tips to help you do just that. Now if you have, indeed, followed those tips then you are probably seeing the positive changes they deliver. Most probably, you are excited to know more.
Well, as promised, here are the rest of our great tips just for you:
- Install Some Storage Receivers
Using storage receiver can help improve the efficiency of your compressed air system in varius ways. For one, when you use a main air receiver at the compressor room, you can make the controller for load/unload compressor much more efficient. It can also help your compressors ride out high flow compressed air demands that can possibly cause another compressor unit to unnecessarily run. It might also require your compressor to run continuously in an unloaded mode just to avoid low pressure events which can be very inefficient, not to mention costly.
Storage receivers that are protected by check valves can also protect your equipment from transient low pressures when your production machinery is affected by localized fluctuations in pressure.
- Replace Equipment to Boost Efficiency
Through the years, the compressed air industry has consistently evolved for the better. All the manufacturers are aware how customers are becoming more and more interested in saving energy. For this reason, they tweaked (some completely redesigned) their equipment to meet the demand for more energy-efficient units. That said, when time comes that you have to do a major repair or maintenance work on your current air compressors, do consider that what you have may not be up to current standards. So instead of investing on the repair of your old compressors, it may be better to replace them with new and much more efficient units. While this may cost you a lot upfront, know that going forward, you will actually be saving a lot on operation and maintenance costs.
- Lessen Component Pressure Loss
One of the most important metrics to check is how much pressure differential there is between the piping drop and the end use of the compressed air. Commonly, you’d see the largest pressure differential happening in the last 30 feet of the pipe. It is in this last section that there could be undersized filters, lubricators, regulators, connectors, hoses, and all the other elements that can possibly be contributing to substantial pressure differential. Of course, this differential may also be found inside the production machinery itself. If this is the case, the discharge pressure at the end of the system should then rise to compensate and this will increase the power costs.
- Perform Leakage Detection Procedure and Repair
Did you know that about 25-30% of the compressed air produced by your compressor actually never makes it to the end user? Yes, that is the average. Imagine how much higher this number can get if you do not implement any leakage detection and repair program in your plant. one of the easiest ways to save on energy is to repair any leaks.
There you go – our finest tricks in optimizing compressed air systems. Follow them and do let us know how they work for you!