Find A Leak To Fix A Leak

December 28, 2015December 28, 2015Ken Bean

Leak Detection

A small leak in your compressed air system may not seem like a big deal. Until you consider that small leak at 1/32” diameter will pass 1.62 SCFM on an air system running at 100 PSIG. That equates to 2,332 SCFM in a 24 hour period. This shows with just a few small leaks, they can quickly add up to the equivalent of several horsepower of compressed air being required just to satisfy the leaks.

The best way to detect leaks is to use an ultrasonic acoustic detector, which can recognize high frequency hissing sounds associated with air leaks. These portable units are very easy to use. Costs and sensitivities vary, so test before you buy. A simpler method is to apply soapy water with a paintbrush to suspect areas. Although reliable, this method can be time consuming, messy and on some applications, near impossible to reach.

Utilizing Compressed Air Storage

December 15, 2015December 21, 2015Ken Bean

If you look at most any industrial compressed air system you will find a receiver located somewhere in the layout. However, just having a receiver does not mean the system is fully utilizing the capability of the storage.

Properly utilized compressed air storage should allow a compressed air system to meet its peak demand needs and help control system pressure without starting additional compressors. The correct type and quantity of air storage depends on air demand patterns, air quantity and quality required, and the compressor and type of controls being used. An optimal air storage strategy will enable a compressed air system to provide enough air to satisfy temporary air demand events while minimizing compressor use and pressure.

To properly utilize the stored compressed air the pressure in the receiver needs to be stored at a higher pressure than the system pressure. The strategy is to allow the differential between these 2 pressures to be sustained by incorporating a pressure flow controller (PFC) and/or metering valves.

This allows the pressure in the demand side to be reduced to a stable level that minimizes actual compressed air consumption. PFCs are added after the primary receiver to maintain a reduced and relatively constant system pressure at points of use, while allowing the compressor controls to function in the most efficient control mode and discharge pressure range. Properly applied, a PFC can yield significant energy savings in a system with a variable demand load.

A professional air audit can determine the proper storage size requirements.

Turn It Off

December 8, 2015December 8, 2015Ken Bean

Those big air compressors in the back that nobody wants to look at consume a huge amount of energy. A 100 horsepower compressor can cost $75,000 per year in energy costs (based on 8,760 hours at $0.10 per kilowatt hour). Utilizing automation, storage and flow control, system balancing and best use practices along with other details, can allow you to turn some compressors off. Just running the above mentioned 100 HP compressor during lunch each day can cost up to $3,000.00 annually.

An Air Audit today could save thousands next year!

Saving Energy On Compressed Air Does More Than Save Money

December 1, 2015August 3, 2016Ken Bean

Approximately 70% of all manufacturers have a compressed air system. These systems power a variety of equipment, including machine tools, material handling and separation equipment, and spray painting equipment. Energy audits conducted by the U.S. Department of Energy (DOE) suggest that over 50% of compressed air systems at small to medium sized industrial facilities have low-cost energy conservation opportunities.

Significant air emissions are released when electricity is produced. A recent study for the state of Minnesota, indicated that one-fourth of the energy-related emissions of carbon dioxide, sulfur dioxide, lead and mercury are from generating electric power. Industry uses over 34% of this electricity. Reducing electricity used by compressed air systems will help improve everyone’s air quality.

A team of qualified auditing engineers is the correct way to evaluate your system.

Contact me today to schedule a consultation.