Compressed air systems are as much a part of an industrial plant as the personnel on the floor. Sometimes, those individuals might use compressed air inappropriately. A few common misuses include drying, sparging, aspirating or atomizing, padding, vacuum generation and cooling personnel, not to mention waste resulting from idle or abandoned equipment.
A compressed air audit and optimization program can be a starting point for getting the most out of a system. In a recent Plant Services survey on compressed air, almost half (45%) of the respondents indicated they’d conducted a compressed air system audit within the past year.
One-third of respondents had indicated that they already had hired a consultant and initiated steps in an optimization program, and only one of them indicated disappointment with the program.
When asked what percent of their plant’s electricity is consumed by compressed air systems, 31% were unaware of the answer; however, almost 34% said it was 5% or less.
Forty percent of participants also weren’t sure what percent of their motor system energy is consumed by compressed air systems, although 27% indicated it was 5% or less.
Preventive actions to take care of compressed air leaks were a bit of a mixed bag, but roughly two-thirds said they repair the leaks, while 17% check for leaks around compressors and air dryers and 9% don’t take any action at all. Other measures included checking joints for leaks, tagging leaks, checking for open bleed valves and checking regulators and tools for leaks.
Steps taken within the past six months included replacing or repairing air filters (63%); replacing or upgrading condensate drains (28%); reconfiguring piping to reduce pressure loss (23%); adding, upgrading or reconfiguring air dryers (22%); adding, restoring or upgrading compressor controls (17%); modifying or replacing regulators (17%); adding compressed air storage (16%); reworking or correcting header piping (15%); installing or upgrading distribution control system (11%); improving compressor room ventilation (8%); replacing current compressor with a more efficient model (8%); adding a smaller compressor for off-peak loads (6%); and installing or upgrading ball valves in the distribution system (6%). Seventeen percent of the respondents indicated they have not taken any steps in the past six months.
When asked about the biggest problem with their compressed air systems, 44% said they have no problems to report, 25% noted excess moisture in compressed air and 18% cited inadequate pressure at points in the system
La-Man's AMD-035 SuperStar Membrane Dryer provides ultra-clean, ultra-dry compressed air
La-Man Corporation's AMD-035 SuperStar Membrane Dryer provides ultra-clean, ultra-dry compressed air. This membrane dryer can be used where refrigerated dryers may be too large, or electricity is not available or desirable.
Exair's PVDF Super Air Knife is suitable for corrosive environments
Exair’s PVDF Super Air Knife provides a laminar curtain of air that can be used to blowoff, clean and dry in highly corrosive environments not suitable for stainless steel. The durable construction of the PVDF Super Air Knife consists of PVDF (Polyvinylidene Fluoride), Hastelloy C-276 alloy screws and a PTFE shim to adjust the force and flow of the airstream.
Kaeser Compressors' Sigma Air Manager with 3D Control responds to switching losses, control losses and pressure flexibility
Kaeser Compressors' Sigma Air Manager (SAM) now features 3D Control. The self-adjusting 3D software responds to switching losses, control losses and pressure flexibility. The controller includes an integral Web-server for remote monitoring of system activity.
Jenny Products' climate-control compressors are powered by a one- or three-phase UL listed electric motor
Jenny Products' climate-control compressor line offers 22 models in single- and two-stage simplex configurations, as well as single- and two-stage duplex designs. Simplex single-stage models come with a 30-gallon tank and horsepower ratings of 1/2, 3/4 and 1. Between 2.9 and 5.9 cfm are displaced at 100 psi.
Atlas Copco's LS and LP piston compressors are available in a range of horsepower increments from 5-30 horsepower
Atlas Copco Compressors has introduced two piston compressor product ranges that are engineered to deliver performance and efficiency. The LS Series two-stage splash-lubricated compressor combines a one-piece aluminum head with a valve design that is engineered to provide volumetric efficiency.
Hitachi's SRL Series Oil-free Multiplex Scroll Air Compressor is available in 7.5 kW, 11 kW and 16.5 kW units
Hitachi America, Industrial Components and Equipment Division, has introduced the SRL Series Oil-free Multiplex Scroll Air Compressor. Features of the SRL Series Oil-free Multiplex Scroll portfolio include 7.5 kW, 11 kW and 16.5 kW units with pressure optimization at 116 PSI or 145 PSI.
Sullair's Stationary Air Power System is designed to meet the demand for oil-free compressed air
Designed to meet the demand for oil-free or instrument-quality compressed air, the Sullair Stationary Air Power System consists of a Sullair rotary screw air compressor, a wet storage tank, a refrigerated or regenerative dryer, customized filters, dry storage and a flow controller.
Dwyer Instruments' Series 644 Industrial Pressure Transmitter features an accuracy of ±0.05% FS RSS
Dwyer Instruments' Series 644 Industrial Pressure Transmitter is designed for high-accuracy pressure applications. Featuring an accuracy of ±0.05% FS RSS (<±0.25% TEB), the 644 offers multiple measurement options with two output choices (VDC or mA) and ten psig pressure ranges (optional 0 to 15 psia).
Automation Products Group's PG10 Digital Pressure Gauge offers at-a-glance readability
Automation Products Group introduces the PG10 Digital Pressure Gauge. This IP65-rated indoor/outdoor gauge features a 5.5-inch display casing, a five-digit display with characters at 0.68 inches tall and a 270° digital “dial” or radial bar graph that shows a user-selectable pressure range from 0 to 100%.