FEATURE COMPRESSED AIR
ARE YOU GETTING THE MAX out of your system?
What is involved in a compressed air energy audit and how can businesses achieve greater efficiencies in plant equipment is discussed by Mark Stone, product manager at Flexion
E
nergy efficiency is a term widely bandied around by industry but when
it comes to processes what can organisations really do to achieve greater efficiencies in their plant equipment? While the process of producing
compressed air can be costly it is also very wasteful; the Carbon Trust estimates that as little as 8-10% is converted into useable energy. As a necessity in a wide range of business operations it is imperative that we better understand how it is currently used, highlighting bad practice and implementing further efficiency measures. A compressed air system audit offers a precise analysis of the existing system with a particular focus on energy consumption. An energy audit should be tailored as each compressed air system is different and application requirements can vary. Energy audits generally fall into three categories: basic (walking the line), data logging and full system but ultimately the audit you choose will depend on the type of operation and budget available.
BASIC AUDIT (WALK THE LINE) A basic audit includes a visual inspection of the compressed air system and can be carried out by in-house experts or compressor manufacturers at no extra cost. Its simplicity enables organisations to complete a basic system analysis on a regular basis, helping to identify inefficiencies or operational weaknesses and put measures in place to help increase efficiency and productivity. Typical recommendations as a result of a basic audit are the use of energy efficient blow guns or nozzles, isolation of idle plant and operator training.
DATA LOGGING Data logging involves tracking and analysis of the system’s performance with a focus on the amount of air delivered, energy consumed and network pressure during operation. This analysis, generally over a seven-day period, will often reveal if the compressor is correctly sized and operating at its optimal performance. As part of the process users will receive comprehensive data sets, giving engineers a tool against which to benchmark future system performance.
6 FEBRUARY 2016 | FACTORY EQUIPMENT
potential pressure drops are occurring across equipment. Unfortunately, compressed air is often generated at the compressor's maximum pressure which can lead to significant inefficiencies. However, reducing system pressure leads to significant savings: 5% by one Bar and considering all systems have leaks reduced pressure reduces the leakage experienced. Through careful monitoring of system pressure users will be able to implement small incremental reductions, resulting in increased energy efficiencies with no effect on operations.
While data logging comes at a cost, payback periods are usually very short.
FULL AUDIT A full system audit can be expensive but typical savings can range from 30-50% when the recommendations are put into practice, usually covering the cost of the investment quickly. The reason such significant savings can be obtained is its holistic view, highlighting the true costs of compressed air and identifying opportunities to improve efficiency and productivity. Generally, a full system audit will analyse performance of power, pressure, flow and temperature under different operating conditions.
POWER
It is vitally important to measure the amount of energy used to operate a compressed air system in order for businesses to estimate annual electricity consumption. This includes measurement of the current voltage utilised by the compressor and the full-load and no-load input power. This should be taken over a predetermined period (usually seven days) and the results can give an accurate overview of the amount spent annually on the production of compressed air.
PRESSURE By measuring the pressure of a compressed air system engineers have access to vital feedback for future control adjustments and to identify where
Generally, a full system audit will analyse performance of power, pressure, flow and temperature under different operating conditions
FLOW METERS Implementing flow meters into the analysis of a compressed air system helps to measure the total flow and determine air consumption. This can be a direct measurement of flow in the pipe or via a calculation based on the inlet vacuum on modulating machines. This allows engineers to record approximate air usage, rate of change and changes in flow associated with wider system events and to make the necessary adjustments to maintain the required flow levels.
TEMPERATURE
Measuring the temperature of a compressed air system during peak operation helps to indicate if the equipment is performing within the parameters set out by the manufacturer. Traditional compressed air systems generally operate below 200°F. Systems that operate at higher temperatures than specified will not perform at peak efficiency. However, many organisations only make a detailed analysis of their system when errors or machine downtime occurs; this hesitancy to invest in regular energy audits can severely affect long term performance. An audit will not only highlight the true cost of compressed air but provide greater transparency of its uses across the business and as a result, opportunities to make savings. Herein lies the opportunity both to lower energy costs and enhance the efficiency of production lines.
ERIKS
www.eriks.co.uk
/ FACTORYEQUIPMENT
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