FEATURE COMPRESSED AIR
FIND AND FIX AIR LEAKS - FAST C
ompressed air is regarded as industry’s fourth utility along with
water, gas and electricity. Like the others it is expensive but too often regarded as a low or no cost item, particularly by machine or plant operators who don’t have to pick up the bill themselves. This lack of understanding is resulting in significant compressed air losses across all industries. Leakages average 30% of the total amount produced with some sites losing as much as 60% of the total air generated. The problem is that this produces an even greater demand to keep up with the losses. Compressed air is produced by air generators which run on electricity which means leakage has an enormous impact on both energy efficiency and a company’s CSR goals. There are several issues that industry needs to tackle in regard to its use of compressed air including inappropriate use, particularly with idle plant and equipment; using higher pressures than necessary; little or no use of energy efficient components and the use of compressed air where other technologies may be more effective. What is required in most cases is a
more systematic approach to compressed air management which should encompass leak detection and identification of potential cost saving areas such as shutting compressors down when not in use or reducing air pressure. For example, reducing air pressure by 1 bar reduces energy consumption by 7%.
WHAT IS MOST APPROPRIATE OPTION? Compressed air users should investigate whether compressed air is the most appropriate option for certain jobs such as cleaning, drying or ventilation. A further option is to use energy efficient nozzles which reduces air
consumption by at least 50% but uses the coanda effect to entrain the ambient air to increase the overall flow and volume of the air jet. However, the first and most obvious step to undertake is a comprehensive audit of the work area, identifying leaks and listing them systematically. Leaks should be physically tagged and a severity attributed to them which will allow an estimate to be made of the potential savings from remedial work. The wastage estimate can then be compared to the potential capital cost of fixing the leak. In most cases this is a fairly straightforward case of replacing
Compressed air
management should be a priority because savings can be considerable with a remarkably fast return on investment for repairs
While the air around us is free by contrast compressed air used in industry is very expensive. Mark Stone, product manager at FLEXION explains how to deal with wastage and misuse
worn fittings, seals, valves and manifolds, making alterations to the air preparation equipment or introducing new working practices for employees. These cost estimates are a vital part of the process as they offer a clear payback period for the work which in the majority of cases can be as little as a few months due to the high cost of compressed air. Cost estimates for leaks obviously varies greatly based on shift patterns, the cost of electricity and the efficiency of air generation on each site. However, a good rule of thumb based on current costs and two eight hour shifts would put the cost of a ‘light’ leak at £100 per year and a severe leak costing many thousands of pounds per annum. With the FLEXION Compressed Air
Savings Programme our recommendation is to effect a first fix where possible such as remaking joints, replacing on-active parts including fittings and gauges. First fix capability depends on being able to access the equipment safely which usually requires isolating the mains air supply. My advice is to get in expert help.
HIGH PRESSURE FILTERS FOR LARGE VOLUME FLOWS
With the extension of the CLEARPOINT HP 50 filter series by models for large volume flows BEKO TECHNOLOGIES completes its range of CLEARPOINT high pressure filters. The HP 50 models are designed for large volume flows of up to 3,500 m³/h and a pressure of up to 50 bar. This is a demanding performance combination which is required, for example, for the production of PET bottles. The new models boast decisive constructive advantages compared to other solutions. Special blockings for example, against leaks that result from the typical pulsations in high pressure networks with
18 SEPTEMBER 2015 | FACTORY EQUIPMENT
piston compressors and an acoustic alarm release in the event of attempts to open the filter housing while under pressure. HP50 resists corrosion through an anodised, powder-coated housing made of a saltwater-proof alloy and aggressive condensates. A constantly high separation efficiency is ensured by the innovative poly-fibre filter material which consists of micro-fine, thermally fused borosilicate and polyester fibres.
BEKO Technologies T: 01527 575778
www.beko-technologies.co.uk
LEAK DETECTION Detecting leaks is fairly straightforward when you have the right equipment and you know where to look. A survey of a medium sized plant by an experienced team can be achieved in around three hours with the use of an ultrasonic detector that is specifically designed for the task. Good ultrasonic detectors can identify leaks from up to 50 feet away even in noisy plant areas and provide an accurate estimate of the severity of the leak. I recommend supplying maintenance personnel or the contractors performing the repair with photographic evidence of the location of the leak to ensure that those responsible have a good visual guide to work from. Compressed air is expensive but often
overlooked when recommendations are made for savings in a production environment. Compressed air management should be a priority because savings from better management and utilisation can be considerable with a remarkably fast return on investment for repairs.
ERIKS T: 01452 522265
www.eriks.co.uk
/ FACTORYEQUIPMENT
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