From time to time, compressed air auditors find air-cooled air compressors located in small rooms where the ventilation is inadequate. Most of the time, in properly designed rooms, the heat the compressors produce is ducted out of the room through metals ducting — often, it will be directed to cool areas of the plant in […]
Air Preparation
Compressed air fail: Inlet valve problems
A mining complex was experiencing low pressure events — even though its 14 large compressors were all running. The pressure was adequate during most of the day, but during peak demand times, the pressure sagged to unacceptable levels. This, of course, caused complaints from the workers. The pressure settings of the compressors were already set […]
Compressed air fail: Capacity surprise
When doing a compressed air audit, it is always recommended to measure the important parameters of the system and analyze the data carefully. Typically, pressure and power (or amps) are monitored, but in some cases measurement of flow comes in handy. In the case of a large plumbing component manufacturer, the installation of flow meters […]
Compressed air fail: Outlet pipe size
A compressed air auditor was assessing a compressor and dryer installation within a compressor room and noticed something strange. On a large air dryer, the outlet flange was of 6-in. size, yet the piping used to connect the compressors and filters to the air dryer was only 4-in. Further to this, the long piping link […]
Compressed air fail: Crud in the lines
A compressed air auditor had a system of measuring devices that was monitoring a compressed air system located in a metal foundry. Pressure, flow, and compressor power were all monitored to help determine if the system was running efficiently and effectively. An additional set of instruments were added to the monitoring suite due to some […]
Compressed air fail: Drive by shooting
A compressed air auditor visited a large mine and was asked to look for areas of improvement. The mine’s manager was interested in reducing the electrical consumption and had a hunch that the compressed air system was a good item to investigate. The facility was a very mature site, so there were many large compressors […]
Compressed air fail: Obsolete compressor controls
Recently, a compressed air auditor ran across a newly rebuilt compressor at a wood products company. The unit was cleaned up nicely and had a shiny new air end due to a rebuild — but because the unit had obsolete controls, this compressor continued to run very inefficiently. Saving money by rebuilding this compressor was […]
QBX proportional electronic regulator for low pressures and flows
Managing pressure regulation in applications with low pressures and low flows is easy with the Proportion-Air QBX electro-pneumatic proportional pressure regulator. With customizable pressure ranges and accurate, repeatable results, these compact devices can improve application performance in nearly any environment. The QBX boasts accuracy of up to ±0.2% and repeatability of ±0.02%, regulating pressures from […]
Compressed air fail: Service factor
Quite often, people are surprised when they measure an air compressor and find the motor is consuming more than rated amps. One of the unfortunate things about the industry is that it is common to see motors are being stretched into the “service factor” in order to get more cfm out of a given compressor […]
Compressed air fail: Artificial demand
One hidden problem in many compressed air systems is something called “artificial demand.” Many users are unaware of the effects of this component of compressed air demand as evidenced by higher than needed compressed air pressures on most systems. Artificial demand in a compressed air system refers to the excess consumption of compressed air caused […]
