FEATURE COMPRESSED AIR
GIVE YOUR SYSTEM THE best chance for a long, healthy life
Easy to overlook the expenses that come with ownership, Mark Whitmore of BOGE Compressors discusses how better care and maintenance can lead to a longer and less costly compressor life
W
hile most manufacturing businesses realise how essential a reliable
supply of compressed air is there will always be some that install a system, overlook maintenance procedures and do not recognise the signs that can lead to imminent failure. For these there is a sense that work and expense begins and ends with installation and from this point on the equipment will take care of itself. However, poor aftercare and lack of
servicing and simply not being fully aware of the total cost of ownership will at some point result in machine failure and expensive repairs which in turn will impact on overall profitability. So how can operators better protect their compressed air system and ensure everything is being done to ensure its long and productive life?
RECOGNISING MOST COMMON CAUSES OF FAILURE In order to understand the fixes and solutions it’s important to recognise the most common causes of failure in a compressed air system. This can often be traced back to an erroneous installation process; when the initial fitting is wrong, predictably, component problems will follow which fall outside of the usual expectancy of wear and tear. A further typical issue leading to failure
is oil leakage which not only damages the efficiency of the compressed air system but in applications such as food manufacture can infiltrate the product and packaging. This can result in severe implications, both in terms of expense and the risk to the health of consumers. An additional issue is that of sudden falls or rises in air pressure which can be the result of air leaks. This is often due to hoses connected to the compressor that have been badly installed or maintained while air leaks can be sourced from valves or other compressor parts. Without proper management air leaks are both a financial and energy burden. Identifying and repairing them can be done on site every day as a matter of course. By checking and recording the pressure on the air receiver for an allotted amount of time at the end of the day the operator can gauge pressure drops in the receiver and determine the current rate of
14 MAY 2015 | FACTORY EQUIPMENT
possible costs is by assessing how much compressed air is actually being used and whether the system is the most suitable one for the application. One way of keeping this in check is by using an intelligent energy management system which provides a transparent and current picture of how efficiently the compressor is performing, thereby helping to keep energy costs under control. Many of the problems and expenses that can arise with a compressed air system can be avoided all together with regular maintenance and aftercare plus appropriate diagnostic monitoring. The traditional method of maintenance was at a fixed-interval with components being replaced preventatively at an agreed point. Parts were sometimes being replaced prematurely when they were still in perfectly good condition while others could fail as they were only being monitored or replaced at certain times. The option of status-based maintenance is widely accepted as being more efficient and cost-effective which operates best in tandem with innovative diagnostic monitoring tools. The data gathered is exactly the
air leakage in the compressed air system. To put this into context the Carbon
Trust estimates that unmanaged compressed air distribution can equate to around 40% of output (or wasted air) and even a small leaking hole of around 3mm can cost a business more than £700 per year in wasted energy1. A further key consideration is that of lubricant choice which can have a huge effect on the energy efficiency and performance of the air compressor. With a stable viscosity and almost no residual deposits a synthetic lubricant can deliver up to 5% energy savings while providing protection from corrosion.
INTELLIGENT ENERGY MANAGEMENT SYSTEM One of the most fundamental factors that is often overlooked by operators is understanding the impact producing compressed air has on energy consumption which is estimated to account for 75% of lifecycle costs. One way of being more efficient and cutting
Even a small leaking hole of around 3mm can cost a business more than £700 per year in wasted energy
information needed to ensure problems are detected at the earliest stage, allowing for intervention and repair with minimal disruption. Providing data is correctly analysed, the compressor can continue operating at its optimal level of efficiency and reliability. This in turn helps to keep down the cost of servicing and guarantees the best possible return on investment. While all of these suggestions and processes will enhance and improve the performance of a compressed air system, continued success and prolonged productivity can be better guaranteed by a robust service package. After all, a compressed air system may in itself be a brilliant piece of engineering but it needs the help of experts and support of excellent aftercare and diagnostics to keep it that way for the long haul.
BOGE Compressors T: 01908 533253
www.boge.co.uk Enter 306
/ FACTORYEQUIPMENT
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