Compressed air: Find the leaks, lower the pressure, and measure the results

12/28/2012


The “better practice” would measure compressor power before and after reducing pressure so the reward can be more accurately quantified before impacting a variable that influences operations. Compressor load conditions relative to time would be required to estimate savings.

For centrifugal compressors, engineering data corrected to site conditions and ambient temperatures is essential to estimate any potential savings. Depending on ambient conditions and internal components used in a given compressor, reducing pressure may have no impact on power.

Reducing system pressure can also impact compressed air demand. A common misconception estimates potential savings as a function of peak demand and system pressure. The actual influence on demand is a function of the change in pressure at the point where the gas is expanded. A better estimate will require detailed monitoring and analysis of a given system across all load conditions. Although energy savings can be realized easily by simply reducing compressor and system pressure settings, it is typically executed as an event. Sustaining results can be challenging.

For any production issue associated with compressed air, pressure is the most frequently assumed problem. Most facilities will prioritize measured production results over assumed compressor energy savings. As a result, restoring pressure settings to previous or higher settings is the typical response. 

Measure the results

The “best practice” for compressed air systems requires a transition from executing random immeasurable events to a formal program with performance metrics and a team of individuals accountable for delivering monthly performance goals. When compressed air system performance goals are owned at the appropriate level within an organization, any negative variance is corrected. By focusing on delivering and sustaining reported results, compressed air system efficiency would be practiced regularly. With the appropriate level of visibility and accountability, an increase in leaks would be quantifiable, resulting in specific expectations with measurable results executed as a maintenance practice, not an isolated task. 

Mark Krisa is director of Ingersoll Rand’s Global Service Solutions.


<< First < Previous 1 2 3 Next > Last >>

ROBERTO , TX, Brazil, 01/11/13 04:55 PM:

A no load test , made in a holiday gives you also a good measure of your invisible losses
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
Each year, a panel of Control Engineering editors and industry expert judges select the System Integrator of the Year Award winners.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
This eGuide contains a series of articles and videos that considers theoretical and practical; immediate needs and a look into the future.
Learn how to create value with re-use; gain productivity with lean automation and connectivity, and optimize panel design and construction.
Go deep: Automation tackles offshore oil challenges; Ethernet advice; Wireless robotics; Product exclusives; Digital edition exclusives
Lost in the gray scale? How to get effective HMIs; Best practices: Integrate old and new wireless systems; Smart software, networks; Service provider certifications
Fixing PID: Part 2: Tweaking controller strategy; Machine safety networks; Salary survey and career advice; Smart I/O architecture; Product exclusives
The Ask Control Engineering blog covers all aspects of automation, including motors, drives, sensors, motion control, machine control, and embedded systems.
Look at the basics of industrial wireless technologies, wireless concepts, wireless standards, and wireless best practices with Daniel E. Capano of Diversified Technical Services Inc.
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
This is a blog from the trenches – written by engineers who are implementing and upgrading control systems every day across every industry.
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

Case Study Database

Case Study Database

Get more exposure for your case study by uploading it to the Control Engineering case study database, where end-users can identify relevant solutions and explore what the experts are doing to effectively implement a variety of technology and productivity related projects.

These case studies provide examples of how knowledgeable solution providers have used technology, processes and people to create effective and successful implementations in real-world situations. Case studies can be completed by filling out a simple online form where you can outline the project title, abstract, and full story in 1500 words or less; upload photos, videos and a logo.

Click here to visit the Case Study Database and upload your case study.