FEATURE u Compressed Air
Compressed air: Five top tips for
sustainability By Libby Peacock, Category Manager – Fluid Power, Brammer Buck & Hickman
G
enerating compressed air is energy intensive and expensive, frequently with a considerable percentage – up to 30
per cent – wasted or misused. But is it possible to reduce energy usage without negatively affecting a machine’s performance and without significant expenditure? The answer is a resounding yes, by using the ‘marginal gains’ theory that is based on the premise that small yet significant improvements can lead to substantial results. At Brammer Buck & Hickman, we have applied this theory to compressed air usage. Here are our top five marginal gains tips to reducing compressed air energy consumption:
TIP 1: CHOOSE THE CORRECT COMPONENTS Switching to high flow couplings could increase the productivity of air tools by some 50 per cent and reduce energy consumption by up to 30 per cent. In more than half of all applications, the pneumatic drive is too large for the intended purpose. Simply downsizing the cylinder or using single acting cylinders are often all that is required of a pneumatic system and can help reduce air consumption.
TIP 2: HOSE AND TUBING SIZES Opting for a tubing size with a smaller diameter for valves and cylinders can reduce air consumption, while choosing a larger diameter hose for air tools can save money. Using tubing with low drag co-efficiency can increase air flow and reduce pressure drops to optimise compressed air systems to achieve yearly savings of around £15,000.
TIP 3: REDUCE THE PRESSURE Incorporating pressure regulators at point of use can very quickly pay dividends. Reducing the pressure by just one bar can see up to a 10 per cent reduction in energy usage. Installing a regulator means the pressure may be reduced without having a negative effect on the operation of the machinery. As well as wasting compressed air, operating at too high a pressure can increase wear on the components leading to burnout and the associated maintenance and replacement costs.
TIP 4: SWITCH OFF AND SAVE Pneumatic equipment left idling can consume between 20-70 per cent of its full load power. Apply responsible usage principles to pneumatic components such as: installing manual shut off
valves and switching off when machinery is not in use; implementing time-operated solenoid valves which allow the operation of pneumatic components only if a subsequent piece of equipment is in use; or installing sensor-operated interlocks which detect the need for compressed air equipment to operate can isolate or apply air as appropriate.
TIP 5: STOP LEAKS In a pneumatic system, leakages can account for between 5-10 per cent of the air supplied, although some systems record a loss of 40-50 per cent of the air input. One of the biggest sources of air leaks are push-in fittings, although it’s probably not the fitting that’s to blame but the tube. Using scissors, box cutters and the likes to cut pneumatic tubing can compromise the seal and cause the fitting to leak. Using a tube cutter ensures a good seal. Consider installing a flow meter, which is the
most effective way of reducing leaks and energy consumption, by monitoring leaks as part of a facility wide maintenance programme. You might also want to consider investing in a Compressed Air Leak Audit to fully identify leaks so you can take remedial action.
These small adjustments are easy to make without the need for any costly equipment or intervention from third parties. In fact, they can be done by some of the most junior employees, ensuring everyone can participate in the move to more sustainable processes. At Brammer Buck & Hickman we regularly
run workshops on compressed air under the name of ‘REHAB’, which stands for: Reduce Energy, Education, Health & Safety, Autonomous Maintenance, and Best Practise. These workshops are designed to empower customers to make changes for themselves and the response is always one of astonishment when we can prove together, with hands on training, how minor adjustments can generate significant results.
Brammer Buck & Hickman
https://uk.rubix.com
32 June 2022 Irish Manufacturing
www.irish-manufacturing.com
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