Raising the efficiency of compressed-air systems could save thousands of dollars yearly. Save air with a regulator added to a valve bank. Placing FRL elements on scheduled maintenance intervals reduces pressure drop and lets air flow. Compressed air is considered the "fourth utility" in many industrial plants after electricity, gas, and water. A study by the U.S. Dept. of Energy found air compression accounted for approximately 8.6% of overall industrial energy consumption. Generating compressed air for a pneumatic system requires a huge amount of energy, but many companies do not consider it as a cost of production. Compressed-air production is a variable expense. There can be significant savings in operating costs when it is monitored and controlled. These savings can be divided into three categories: energy, maintenance cost, and better operational efficiency. Following are techniques to manage both the supply side (compressors and air-treatment equipment) and demand side (distribution, storage systems, and end-use equipment) of a compressedair system. They can save dollars while work continues at an equivalent or improved level. The most obvious source of "found money" from a compressed-air system is in fixing air leaks. Much has been written about air leaks. However, there are new audit and detection methods worth revisiting. It is not unusual for a well-maintained plant to have a leak rate of around 20% of total compressed air production. A single 1/16-in. leak can cost $750/yr while a 1/4-in. leak can run close to $12,000 using an energy cost of $0.07/kW-hr. The majority of leaks will not be found at the primary header and piping, but at the valves, connections, fittings, tools, and at the point of use. It is often possible to repair the leak by simply tightening threaded connections, or removing the fitting and properly applying thread sealant. Push-to-connect fittings on plastic tubing
Products & Services
Compressor Repair Services
Compressor repair services repair and rebuild used compressors and systems such as air compressors, gas compressors, refrigeration compressors, and air conditioning compressors.
HVAC ductwork includes pipe or closed conduits made of sheet metal, fiberglass board, or other suitable material for conducting air to and from an air handling unit.
Compressed Air Filters
Compressed air filters are used to remove water, oil, oil vapor, dirt, and other contaminants from a compressed air supply.
Air Knives are pressurized air plenums containing a series of holes or continuous slots through which pressurized air exits in a laminar flow pattern. The exit air velocity then creates an impact air velocity that can range from a gentle breeze to a powerful stream.
Topics of Interest
Wasting compressed air is usually harmless
to the environment. This may be the reason
why air leaks are often not taken seriously.
The fact is compressed air is the most
expensive energy available in...
Like a furnace that heats a home that's well insulated,
a compressed air system with a minimum amount
of leaks is more energy efficient and more effective.
Leak reduction is one of the most...
Built-in flow sensors improve machine efficiency, reduce downtime, and cut costs. New sensors continuously monitor airflow and consumption to help ensure product and process quality and minimize...
Ultrasonic leak detection has been used for a variety of applications ranging from energy reduction by locating compressed air leaks to quality assurance inspections such as locating wind noise and...
By Christina Galitsky, Sheng-chieh Chang, Ernst Worrell, and Eric Masanet, Berkeley National Laboratory, Environmental Energy Technologies Division Compressed air distribution systems should be...