ENERGY MANAGEMENT
BSEE
Top compressor efficiency tips for 2021
As 2021 arrives, those operang compressed air systems will now be planning how they can best enhance the eciency of their compressed air installaons going forward. Parcularly in light of Covid19, many operators will have more restricted budgets available, or there may be delays to capital investment plans.
A s a result,
maximizing the efficiency of a compressor is key. Here, Musa Jobarteh,
Distribution Development Manager, Aftermarket – UK, Ireland & Northern Europe at Ingersoll Rand, outlines his top tips on how to deliver real efficiency gains for a compressor, in order to save money and deliver reliable compressed air services to a site.
Always choose genuine
All compressed air system will require components such as filters, valves, seals and oil to be replaced. To assure the efficiency of a compressor, however, it is critical to stress the importance of investing in genuine spare parts and lubricants, rather than non-genuine alternatives.
Non-genuine filters, for instance, are more likely to have reduced dust and dirt-holding capacities, which means contaminants can easily enter a system. Alternatively, a non- genuine lubricant can place extra demands on the filter element, resulting in dust and other particles coming into contact with internal compressor components, invariably leading to performance deterioration.
Genuine parts are manufactured to meet the same standard as the compressors that they are intended for. The same is true of genuine lubricants, which are formulated with additives to enhance compressor performance, while ensuring the correct lubrication, cooling and anti- wear qualities are maintained.
Leaking profit
Be sure to manage pipework leaks, as air leaks are the leading cause of energy loss in industrial air systems, wasting as much as 20 to 30 per cent of the system’s output. There are many reasons for leaks in a compressed air system, including shut-off valves and manual condensate valves being left open, as well as leaking hoses, couplings, pipes, flanges and pipe joints. In fact, the Carbon Trust reports that a leak as small as 3mm can cost over £700 in wasted energy. One solution is a simple leak detection survey, which can identify any problems quickly so remedial action can be taken. Alternatively, a flow meter is a reliable means of evaluating compressed air generation and downstream inefficiency costs. Indeed, finding and repairing one 3mm leak could potentially save enough money to cover the cost of purchasing one. Another solution is an energy audit, which can help identify any leaks and ensure these are managed effectively.
Warm up to heat recovery
An energy audit can also be used to quantify a compressor’s possible heat potential. As 94 per cent of compressor-generated heat is recoverable, this can prove invaluable for businesses looking to make efficiency gains.
Heat can be recovered through a variety of processes. This includes installing an energy recovery unit that is fitted to the oil circulation system, or through space heating – recirculating warm air from the compressor to a local area. This energy can also heat water supplies in manufacturing processes where heated water is required, such as central heating, hot water washing and steam systems.
Size a system correctly
A key means of reducing a compressor’s total lifecycle costs is to ensure it is sized correctly for the job it’s required to perform. Over- specifying is unnecessary and can be costly in terms of the initial outlay and any on-going maintenance. Instead, the compressor’s performance can be improved by appropriately sizing it for the demands placed upon it. Engineers need to know the maximum and minimum air pressures, and the compressed air flow required by the system. On existing systems, this information can be measured by installing a data- logging device, which audits and saves the required data. This data can then be used to select the right compressor for the job, eliminating the risk of specifying under or over the system’s requirements.
Take advantage of insights
The Internet of Things and data analytics can help operators to understand how efficiently a compressor is running, and whether any improvements can be made. These insights will not only help highlight any potential issues now, but also enable operators to forecast any potential future problems, based on deteriorating machine performance.
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Predictive maintenance models based on real-time data can be established to help reduce energy consumption, improve process efficiencies and limit any risks.
Managing maintenance
It should go without saying that on- going servicing and maintenance is necessary to make sure equipment runs reliably and efficiently. Investing in a full-service maintenance contract with a proven and trusted compressed air supplier will help provide assured peace of mind, who can ensure regular maintenance and servicing is carried out to the highest standards.
It’s worth noting that there are many benefits to be gained from working with a single supplier for all of company’s industrial air needs. Should a site not only have a compressed air system but potentially vacuum pumps and blowers too, then this means all the equipment can be checked in a single visit. This minimises any disruption to a business’ operations, while also helping to reduce administration time and cost.
Generating efficiency gains
Generating compressed air accounts for 10 per cent of total energy costs in industry, so ensuring wastage is kept to an absolute minimum should be a key concern for all operators. And with industry averages suggesting energy costs account for more than 80 per cent of a compressor’s total cost of ownership, steps – such as the above – that can be taken to help identify inefficiencies and improve a system’s performance should be welcomed. By following these top tips, operators can expect to considerably improve the efficiency of their compressed air system.
www.compair.com BUILDING SERVICES & ENVIRONMENTAL ENGINEER JANUARY 2021 17
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