Archive for November, 2010

How to make Compressed Air Energy Efficient

Wednesday, November 24th, 2010

It is crucial to your business to make compressed air usage as energy efficient as possible. There are several steps you can take in order to do this which won’t take long periods of time but could make huge savings on your energy costs.

Make sure you know all the applications which used compressed air in your factory. If you can, identify the flow and pressure requirements of them. Doing this will help you to recognise if compressed air is being used for any unsuitable applications.

Calculate the usage costs of compressed air by monitoring the compressor operating hours and load cycle at regular intervals. Ensure that all compressed air equipment is maintained to manufacturers’ specifications.

Set a target for increasing cost-effective leak reduction. A feasible aim would be 10% for industrial applications. After any leaks have been repaired, re-assess the compressed air system supply. A general rule is that an extra 1% of operating costs of energy applies for each increase of 2psi operating pressure.

Shut of the air flow to any unused equipment as far back in the system as possible and decrease the distance at which the air travels through the distribution system.

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Compressed Air Filters

Friday, November 19th, 2010

Compressed air filters are essential to the efficient running of applications. Using the correct type of compressed air filters will be beneficial for the short term and long term in order to prevent any problems with equipment and thus saving on downtime and component replacement costs.

There are five key components of a standard air compressor:

1.       Air inlet – A female NPT thread is used to connect the air line using a choice of fittings. The cap is plumbed    internally to direct air flow downwards into the filter bowl. The spiralling action which is created removes water and debris from the air.

2.       Filter cap – This can be either plastic or metal and controls the direction of the air flow.

3.       The dotted line – This shows the path of the compressed air as it flows towards the filter discharge. In order to exit the filter, the compressed air is required to have the spiralling action and continued through the filter element, so that the air is purified further.

4.       Filter discharge – This component allows air to flow from the filter and down the air line to enter the application.

5.       Filter element – The filter element traps any debris within the air flow trying to make its way through to the application. If there is not enough air getting through to the application then always check the filter element and unclog it to allow the air to flow freely.

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Compressed Air Regulators

Wednesday, November 10th, 2010

Compressed air regulators are used to lower the pressure or some of it, coming from the receiver of the air compressor and channel it to the correct areas, depending on where the regulator has been fitted. The reason for this is that the pressure of an air compressor can be higher than you need and compressed air regulators can adapt the pressure to suit the application. Compressed air regulators are only able to lower pressure, not increase it.

Whenever the compressor cycle is on, pressure builds up in the system receiver. This can have a detrimental effect on the air compressor as any sudden increases in pressure will produce a pressure-pulse in the compressed air. A receiver will help to dampen the pulse but not entirely. By setting the PSI to 120 on the high side, 100 on the low side and at 90 for entering the application there should not be any fluctuation in pressure.

Compressed air regulators can be either relieving or non-relieving, depending on the application. A non-relieving system would be used for preventing toxic or expensive gas from entering the atmosphere of the plant. Relieving regulators are used for most industrial applications. If the downstream pressure exceeds the pressure setting on the regulator then it is released back into the atmosphere.

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