FEATURE COMPRESSORS & COMPRESSED AIR
Musa Jobarteh, distribution development manager, Aftermarket – UK & Ireland at Gardner Denver, gives his top five tips on how to achieve compressed air system efficiency
I
t’s a new year and a new decade, and those operating compressed air systems
will be planning how they can enhance the efficiency of their installations going forward.
1. ALWAYS CHOOSE GENUINE All compressed air systems 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.
2. LIMIT LEAKS 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
12 FEBRUARY 2020 | PROCESS & CONTROL
TOP TIPS FOR IMPROVING COMPRESSOR EFFICIENCY
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
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.
3. 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.
4. 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.
5. 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. Predictive maintenance models based
on real-time data can be used to reduce energy consumption, improve process efficiencies and minimise any risks.
MINIMISING WASTAGE 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 tips, operators can
expect to considerably improve the efficiency of their compressed air system.
Gardner Denver
www.gardnerdenver.com/industrials
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44
