Compressed Air Systems

Operating compressed air systems can be expensive. By managing them more efficiently or taking a few proactive steps, you can lower your energy costs and save. Here are some simple steps to help you save on your compressed air systems.

• Inspect and repair systems
• Continuously monitor compressed air system
• Use compressed air systems at necessary times only
• Replace drain valves
• Set pressures according to required processes
• Upgrade your compressor filters
• Maintain air receivers
• Examine purge cycle on dryers

Inspect and repair systems

Leaks are a significant source of wasted energy in a compressed air system, often wasting as much as 20 to 30% of the compressor's output. Compressed air leaks can also contribute to problems with system operations. Fluctuating system pressures cause air tools and other air-operated equipment to function less efficiently, possibly affecting production.

Repairing leaks can save up to 50% of your compressed air annual energy costs.

Continuously monitor compressed air system

On a continual basis, monitor, check and inspect all components of your compressed air systems for wear, proper temperatures and settings, leaks, proper lubrication and clogged filters.

Use compressed air systems at necessary times only

Use compressed air only when and where it is necessary. Shut down your central compressor during non-working hours. If small amounts of compressed air are required, separate those uses from the main system and supply them from a smaller compressor, such as fire sprinkler systems.

Replace drain valves

Consider replacing your old drain valves with new electronic sensing drains which discharge only when necessary. This can save you five times the purchase price in wasted air each year. Older mechanical float type drain valves often get stuck open and timer-based drains open when not needed.

Set pressures according to required processes

Maintain air pressure at the lowest pressure acceptable. Evaluate your pressure requirements carefully. Some facilities operate at higher working pressures to satisfy small high-pressure applications or to compensate for pressure drops from undersized piping.

Upgrade your compressor filters

Replace old compressor filters with new energy-efficient filters with lower pressure drops.

Maintain air receivers

Maintain the air receiver in good condition and ensure it is drained effectively at regular intervals. A timer and solenoid valve can help. Install compressor air intakes where they will receive the coolest air available.

Examine purge cycle on dryers

Examine the purge cycle on dryers. Often, dryers are purged for longer than is required to dry out material.