COMPRESSED AIR


Simple maintenance steps to lower running costs


Through its 10% Taskforce campaign, the British Compressed Air Society (BCAS) hopes to educate operators on the steps that can be taken to lower compressed air electricity consumption. Vanda Jones offers advice on some of the key maintenance techniques.


Vanda Jones


Executive director at British Compressed Air Society


www.bcas.org.uk T


be in the system’s energy consumption and maintenance in the ten years after the initial purchase. Maintenance is also a vital part of


he 10% Taskforce is a call for UK businesses to take simple steps to cut their compressed air energy usage


figure by 10%, with the potential to save a significant amount in wasted electricity costs, while saving of over 411 thousand tonnes of CO2. With the ongoing high cost of electricity, coupled with carbon reduction targets, operators are keen to reduce their site’s overall energy usage and costs. However, many simple energy-saving measures related to their compressed air system can be overlooked. As the UK’s trade body


representing compressed air system manufacturers, distributors, and end users, BCAS advises regularly on the numerous ways that customers can improve the efficiency of compressors. However, many operators may feel that this will require significant investment in new capital equipment, when often, taking small, incremental steps can have a significant impact on energy consumption.


The benefi ts of maintenance A key challenge for operators therefore is to improve bottom line productivity by reducing overall cost of ownership – and effective compressed air maintenance can play a key role. Many end users are now considering


the total cost of equipment ownership over its entire life, rather than just its initial capital price. And this is important, because over 80% of this cost base can


EIBI | MARCH 2024


the overall cost base, to keep both the efficiency and whole life costs of a compressed air system down. End users are realising that moving towards regular routine maintenance rather than reactive maintenance is far more cost effective and will help to reduce unplanned downtime.


Compressor location Compressors should always be located in a dry, clean, cool and well- ventilated area. It takes more energy to compress warm air, yet some compressor plant rooms can run at temperatures as high as 30°C. This can cause more frequent breakdowns as well as wasting energy. Installing extra ventilation will help


to keep the compressor room as near to ambient temperature as possible, placing less strain on the compressor and contributing to better performance.


System design A compressed air system is just that – a system – and each component part needs to be maintained regularly to help maximise efficient performance. Inspecting for air leaks in the


compressed air pipework can pay dividends, as even the smallest leak can result in significant wasted energy and associated costs. Just one 2mm


hole in the pipework could cost over £1,249 per year in wasted energy, so implementing a regime for regularly inspecting and remedying can help lower operating costs. A high leak rate can also cause fluctuations in pressure, resulting in hidden costs such as slower running or even production downtime, not to mention a noisy environment for staff. Inlet filters should also be checked


routinely and replaced before the pressure drop across them becomes significant. Finally, regular maintenance checks should extend to the entire system and encompass ancillary equipment, such as dryers, filters, air receivers and pipework.


Genuine spare parts A compressor, like any piece of industrial equipment is a machine and all machines experience wear and tear. At some point component parts will need to either be repaired or replaced. Operators should therefore always


specify genuine spare parts and avoid the temptation of alternatives which may appear initially to have a lower purchase price but can affect the running of the machine and its overall efficiency. In the long term, using spare parts that are not designed and tested for the specific machine can result in cost increases in excess of 25%. It is also advisable to question the


Even the smallest leak can result in significant wasted energy and costs


compressor supplier’s policy on spare parts availability and obsolescence, as a compressed air system is a long- term investment, and any downtime can be a significant production cost. End users should therefore take the


time to check the credentials of the equipment manufacturer and of the supplier that will be responsible for maintenance. In addition, the ongoing availability and the longevity of the spare parts as well as the service levels


Regular maintenance checks should extend to the entire system and encompass ancillary equipment, such as dryers, filters, air receivers and pipework


provided by the maintenance provider are key in the decision-making process.


Safety matters A vital part of safely and efficiently managing a compressed air system is in the installation, servicing and auditing – all of which have varying amounts of regulation. Just like other items of industrial equipment, the compressor needs to be installed and maintained correctly to ensure it offers maximum performance and operates safely. As a result, we continue to remind all


compressed air end users to ensure that their employees are fully trained on the requirements of the Pressure Systems Safety Regulations 2000 (PSSR), and the importance of the written scheme of examination.


Predictive maintenance Reactive maintenance was, for many years, the default option, where a compressor developed a fault and was subsequently repaired. This could often lead to production downtime and the associated financial losses, so programmes were developed to introduce preventative maintenance regimes. Now operators can benefit from


predictive monitoring and the opportunities that Industry 4.0 and increased data analytics can offer in maintaining their compressed air system.


By implementing a range of simple


yet effective maintenance techniques, and advocating for proactive measures over reactive approaches, businesses can significantly lower operating expenses and enhance system performance. ■


29


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