Air Compressors Info

Approximately 10 % of all electrical power used in industry comes from compressed air. This is proof of its widespread usage but it is also evidence of the potentially large saving in costs which could be achieved if the energy management opportunities are put into practice. Normally, the purpose of compressed air systems in the industrial sectors is to deliver the necessary volume of air at the required pressure and temperature to the correct places. Compressed air is used for operating pneumatic equipments, cleaning purposes, and other general services. This is accomplished by a distribution system consisting of pipes, valves and fittings. The Compressed Air pipe work is arranged in the form of ring mains with interconnections to points of end-users. Careful evaluation of existing compressed air systems can ensure against improper operation, and poor energy utilization. Alert design, operations, and maintenance personnel, with an awareness of energy management, can achieve signif...

Let's continue from [ Compressed Air System Energy-Reduction Case Study (Part 1) ] Compressed Air Energy-Reduction Strategy Project Goals and Implementation Following the IAC assessment, FUJIFILM’s maintenance team formulated project goals and an implementation plan that centered on the utilization of existing facility infrastructure and equipment. The team’s implementation strategy was divided into three phases and focused on increasing the system’s storage capacity to handle production peaks and valleys; lowering air compressor operating pressure; repairing system leaks; and ultimately, operating the facility with one compressor. The team’s strategy was also aided by the company’s closure of its Orange Park, Florida, operations. This facility housed a 75 horsepower (HP) air compressor, a dryer, and a receiver, which the Dayton facility incorporated into its efforts. Project success, then, depended on the accomplishment of four specific goals: To increase system redundanc...

FUJIFILM Hunt Chemicals U.S.A. Achieves Compressed Air System Energy-Reduction Goals with a Three-Phased Strategy. In an attempt to eliminate equipment failures and downtime issues associated with the plant’s compressed air system, FUJIFILM Hunt Chemicals U.S.A.’s in-house maintenance team worked with a team of faculty and students from the Tennessee Technology University Industrial Assessment Center (IAC) to conduct an assessment at its Dayton, Tennessee, facility to identify opportunities for improvement. Following the assessment, the team formulated an implementation plan that would increase the system’s reliability, reduce system maintenance costs, reduce the facility’s overall energy use, and eliminate the use of nitrogen when compressed air systems are down. The Energy Situation The Dayton facility was experiencing excessive downtime due to chronic air compressor failures and significant inefficiencies throughout its compressed air system. In 2007 alone, system operating costs...

Stabilizing system pressure is an important way to lower energy costs and maintain reliable production and product quality. The need to stabilize system pressure should be guided by the compressed air demand patterns and the minimum acceptable pressure level required for reliable production. High-volume intermittent air demand events can cause air pressure to fluctuate, which is often misinterpreted as insufficient pressure. In some cases, improperly set compressor controls will cause another compressor to start, but because of the time required for the new compressor to ramp up, there will be a shortfall of air supply to the system. Such a delay can cause the system pressure to decay, resulting in lost production. Three methods can be used to stabilize system pressure: adequate primary and secondary storage, Pressure/Flow Controllers (P/FCs), and dedicated compressors. Primary and Secondary Storage One or more compressed air applications having large, intermittent air demands can...

Removing condensate is important for maintaining the appropriate air quality level required by end uses. However, significant compressed air (and energy) losses can occur if condensate removal is done improperly. Excess compressed air loss during condensate removal can occur due to several factors. Following shows several condensate removal methods and the characteristics of each method. Manual operation: Operators manually open valves to discharge condensate. Depends on people opening valves at the appropriate time for the necessary amount of time. Often leads to excess loss because air escapes when the valves are left open to drain the condensate. Level-operated mechanical float traps: Use a float connected by linkage to a drain valve that opens when an upper setting is reached and closes when the drain is emptied. Require considerable maintenance. Are prone to blockage from sediment in condensate. Are prone to getting stuck in open position (leak excess air) and in the ...