A large foundry had four large 200-hp air compressors that were water-cooled and were having overheating problems.Β The units were capable of inlet modulation control,Β where the inlet valve of the compressor closes off the intake to control the output flow.Β Use of this control mode reduces the flow output of the compressors and the […]
Air Compressors
Compressed air fail: Dryer overload
A building products company purchased a compressor with 1,520 cfm capacity to help with the increased load after a plant expansion. Various dryer sizes were available, but one sized at 1,600 cfm was selected, rather than choosing the next size up, to save purchase costs. Shortly after installation, the production machine operators started complaining about […]
The magic of compressed air heat recovery
A facilities manager at a building products plant attended a compressed air efficiency seminar sponsored by his local utility. He learned about optimizing air compressors, filters, dryers, and piping. He discovered how to arrange to have a baseline taken of his compressed air system to assess its efficiency. He discovered the excellent savings he could […]
Compressed air fail: Donβt forget the dryer!
A pump manufacturer implemented a new compressor control strategy that was intended to save energy.Β The c0mpany had three compressors running β one fixed speed unit and two VSD style units β and found after studying the system they only needed two compressors to feed the load.Β Savings could be gained by automatically turning a […]
What is the best compressed air adjustment location?
A common question posed to compressed air experts is βWhat component should I adjust to get my compressed air system running more efficientlyβ? The common answer is, βYou should adjust that thing located between your ears.β Compressed air professionals commonly find poorly maintained and incorrectly adjusted equipment when they visit their customersβ compressor rooms.Β And […]
Compressed air fail: Regulator size
An industrial component manufacturer had a system of five compressors located in an interconnected system spread between two buildings. The system pressure of the system was constantly running near 120 psi because of some critical high-pressure applications. Most of the production machinery was rated at 90 psi pressure. The facility manager was sure something could […]
Compressed air fail: Sizing bigger
A seed cleaning company was looking to expand its operations by purchasingΒ new compressed air using equipment. Plant people spoke with the sales engineer β who informed them that each proposed cleaning machine required a minimum of 50 cfm of compressed air.Β Doing quick addition in his head, the engineer calculated they would need a […]
Why manufacturers are walking on air with IIoT
Industrial Internet of Things (IIoT) technologies are placing compressed air systems front and center, despite usually being in the shadows. Contributed by Graham Coats, Sales Director at CMC Until very recently, the air compressor has been nothing but a workhorse; a key tool in the manufacturerβs toolbox, certainly, but one thatβs kept away in the […]
Compressed air fail: Placebo effect
A large industrial user installed a pressure/flow controller in its system to regulate the plant pressure to a constant level.Β The lower plant pressure reduces the extra flow (called artificial demand) that is caused by running production machinery at a higher pressure than is needed.Β The lower the flow, the lower the electricity bill.Β Flow […]
Compressed air fail: Read the problem
A sawmill purchased a VSD compressor to renew its compressed air system and gain savings.Β The equipment was installed, commissioned and was running for a number of weeks before a compressed air expert visited the site. The first thing he did was go to the compressors and read the load and operating hours.Β Compressor controllers […]
