Top 7 Compressed Air power salvage Tips

Would you like to sacrifice electrical costs related to your compressed air system? More than likely - you can. Start by determining your each year compressed air electrical costs by using this formula:

Brake Horse Power X 0.746 X each year Hours of operation X Kwh (Kilowatt-Hour) Cost (divided by) Motor Efficiency

Note: 1 Cfm (Cubit Feet per Minute) @ 100 Psig (pound-force per quadrilateral inch gauge) For 8760 Hours Cost 0.00 Per Year In Electrical Cost

Next...follow these Top 7 Compressed Air power rescue Tips:

1. Fix your Air Leaks

If you do nothing else - corollary this one tip: Find and fix your compressed air leaks. Air leaks are industrys' "biggest looser"!

The midpoint plant loses 20% to 30% it its compressed air through manifold small air leaks. The money spent on man power and parts to find and fix these leaks is well worth it. Note (a 1/4 inch hole will flow 103 cfm @ 100 psig)

2. Change to artificial Lubricants

If you are using petroleum based lubricants, you could touch up to an 8% power savings by switching to Compressor artificial Lubricants. Plus increase tool life and save on oil changes and disposal cost.

3. sacrifice Plant Operating Pressure

If inherent - sacrifice whole plant pressure. Less pressure > Less Cfm used > less power consumed.

Tip: sacrifice plant pressure 2 pounds at a time, then test run for minimum 24 hours. If any tool has issues...then increase pressure 2 pounds until running smoothly again. For every 2 pound pressure allowance -you save 1% of the electrical cost to run the air compressor.

4. Check Differential Pressure on Air Compressor Filters.

Start at the compressor cabinet filter then check the compressor inlet filter.

Note: A dirty inlet filter can cost you 1% to 3 % in added electrical costs. Why? Because decreased air flow to the compressor inlet valve increases the compression ratios resulting in more run time.

Next check the air/oil separator differential pressure under a full load. A new separator causes a differential pressure drop of practically 2-3 psig. When your pressure drop reaches 8-10 psig, then it is time to Change your separator elements. A dirty separator element can cost you up to 5% in added electrical cost.

Next Change the operate air filter element. This often over looked, but still leading filter where the controls receive their air signal. A pressure drop here causes the controls to receive the lower pressure signal loading the compressor more and using more electricity.

5. sacrifice the Compressor Inlet Temperature

By reducing inlet air climatic characteristic 10°F below 70°F, you save 2% on electrical usage. Your advantage increases up to 8% on a 30°F degree day. But addition the inlet climatic characteristic 10°F above 70°F will cost you 2% in added electrical usage for every 10°F up to 10% at 120°F. (Inlet climatic characteristic has very slight affect on Lubricated screw compressors)

6. Check Differential Pressure on Compressed Air Line Filters.

Size Compressed Air Filters to be twice (2x) your compressor Cfm flow rate. This will lower your pressure drop practically 2-3 psig and save 1% on power costs. Elements will last twice (2x) as long and you will save on maintenance costs.

7. Know what ability of compressed air your plant needs.

The cleaner & dryer the compressed air the more power used.

Check with the constructor of your tool to determine the ability of air needed.