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 Water-cooled compressors can have an advantage in locations where the ambient conditions are hot — and therefore using air cooled compressors would result in discharge temperatures that exceed the capacity of the air-drying systems. Overloading air dryers could result in free water entering the plant piping system. This would cause contamination of connected machines and […]

An air compressor at a metal processing plant had a troubled life. It started out as a VSD controlled machine, but a fire damaged the controls. Because of this, a new VSD was installed. It didn’t match the old drive, so wiring was altered to accommodate. Next, the drive failed due to dust contamination and […]

A metal processing company had a laser cutter installed in its manufacturing plant to produce accurately fashioned pieces from metal sheets. This machine requires compressed air that is dried to about 35° F for general use but requires a small amount of air to keep the beam path clean —this avoids contaminating the expensive positioning […]

If you are carefully selecting your new compressors by looking at Compressed Air & Gas (CAGI) data sheets, you should be commended. Use of these sheets are a great way to compare compressor energy and flow characteristics between brands of compressors. In this way, you can choose the most efficient machine for your use and […]

A power utility had a 100-psi station service compressed air system that was used infrequently for maintenance. Two 50-hp water-cooled compressors were installed to maintain system pressure during the high flows, but these were overkill for normal times when the compressed air flow was only about 10 cfm. To reduce the number of starts and […]

An industrial compressed air user was having a difficult time with their high pressure compressed air system. The compressed air demand required instrument quality air, so a heatless desiccant air dryer was installed. The dryer uses activated alumina within its chambers to strip off the moisture from the compressed air flow using an adsorption process […]

One little button click can save thousands of dollars in wasted electrical and maintenance costs on air compressors. Recently, a compressed air auditor encountered the same problem in two different plants; operators had failed to select “Auto Mode” on their compressors. Both units were 150-hp lubricated screw compressor installed in a system of multiple compressors. […]

A compressed air auditor was hired to have a close look at the main compressed air system at a farm implement manufacturing plant. Data collection instruments were placed on the system to measure pressure, flow, and power. The auditor also placed a dewpoint meter at the discharge of the compressor room, after the main air […]

One important item discussed in Compressed Air Challenge’s Fundamentals of Compressed Air Systems seminars is leakage. The most common waste category is compressed air. When studies are done looking at leakage rates compared to the total amount of compressed air produced, on average somewhere between 20% and 30% is found at manufacturing facilities (Fig. 1). […]