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 Compressors
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 […]
Oil-lubricated, direct-drive compressors for small- to medium-size operations
ELGi Compressors USA has introduced the EQ Series, a new range of oil-lubricated, direct drive rotary screw air compressors, designed to provide superior performance and reliability to small and medium-sized operations that traditionally use belt-driven air compressors. In line with ELGi’s customer-centric approach, the EQ ‘ELGi Quest’ Series is built for customers requiring reliable compressed […]
Cloud-based data prevents compressed air system downtime
Industry 4.0 aims to increase efficiency, productivity, quality, and sustainability while optimizing supply chains and workforces. It sounds like a tall order, but as more manufacturers adopt the Industrial Internet of Things (IIoT), edge devices, and cloud-based technologies, the more such efforts are realized. Of course, one of the fundamental challenges is extracting and leveraging […]
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 […]
Creating a compressed air leak management plan
Measuring and repairing compressed air leaks can easily reduce energy costs by 10 to 20%. Compressed air is used in factories all over the world to control machines, processes, and pneumatic equipment. It is a safe and easily available medium and can be used in all possible places via hoses and pipes. However, compressed air […]
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 […]
