Top 8 Preventive Ways for Industrial Air Compressor
TheThe most expensive thing in the air compressor is the way to compress the air. Over the lifespan of a typical compressor, energy typically costs several times more than the purchase price of the compressor. The bottom line, maximizing energy efficiency saves you money.
Steps we can take to reduce compressed air energy cost are, we can measure and monitor the compressor system’s energy consumption, flow rate and operating air pressure. Small changes can be made to reduce your operating pressure and energy costs while improving flow rates and output.
Here are a few steps to optimize your compressed air system and save energy costs.
1. Turn Off Air Compressor At Weekends
In a week an air compressor’s only runs for 60-100 hours, which depends on the shift pattern. Turning off your air compressor at weekends and evening can help you to reduce energy.
2. Fix Existing Leaks
Any air that leak is money wasted. So we have to take care of any leakage from the air compressor because it takes energy to generate compressed air. Maximum time air leakage is not audible; to minimize these problems, third-party help is required.
3. Prevent New Leaks
One has to be proactive and look inside your piping system. Clean and dry pipelines assure good quality of air and no corrosion issue. The soil in the pipe is caused by particles in the compressed air. If the air compressor is not filtered, or if the filter is clogged, pressure drops will occur and the risk of end product contamination will increase. Sludge in the pipe is bad news and must be fixed immediately. Dust and sludge in a compressed air piping system will cause corrosion very quickly and will greatly increase the number of leaks. Dried and filtered air compressed air keeps piping clean.
4. Check Drains. Are Your Condensate Drains Stuck open?
Condensate drains should be adjusted periodically to ensure they open as planned or aren’t stuck open. Replace timer drains with zero-loss drains to stop wasting compressed air.
5. Review Piping Infrastructure
Piping system design should optimize the transfer of compressed air at the wanted flow and pressure to the point of use. Escalating the size of a pipe from two to three inches can reduce pressure drop. Shortening the distance, air has to travel further to reduce pressure drop. More the flow in the pipe greater will be the pressure drop. Pressure drop in a pipe increases with the square of the increase in flow, which means if the flow is doubled; the pressure drop will increase four times. Air distribution piping should be large enough in diameter to minimize pressure drop.
6. Change Filters Systematically
Examine and change filter scientifically to ensure the class of air and prevent pressure drops. There are several airline and point-of-use filters within the facility. Those are just as important to maintain as the air compressor and air compressor room filters.
7. Emphasize Proper Maintenance
If a compressor is maintained properly it runs smoothly and efficiently. Periodic maintenance cuts energy costs around one percent and helps prevent breakdowns that result in downtime and lost production. Protect your reputation and profits with proper maintenance.
8. Identify and Eliminate Inappropriate Uses of Compressed Air.
Wrong uses of compressed air include any application that can be done more efficiently or more economically by a method other than compressed air. High-pressure air often is used for cooling or applications where much lower air pressure is required.