Now more than ever, companies are looking for ways to cut costs. When it comes to air compressors, 70% of the lifetime cost comes from power consumption. So here are some ideas and insights to help you keep your electricity costs down.
LOWER THE PRESSURE
We all know that working under pressure can be hard! Every additional bar of pressure can increase your power consumption by 7%. Set your air compressor at the lowest possible pressure for a specific application. Remember that increasing pressure does not compensate for a pressure drop in the system due to leaks, faulty piping, or choked filters. Install a pressure regulator for better control. It’s also important to calibrate your pressure gauges at quarterly intervals.
CHANGE FILTERS ON TIME
While replacing air filters is mandatory to maintain the quality of air, it is also an energy saving opportunity. Delaying an air filter change costs you more than you think! Clogged filters can lead to pressure drops and hamper efficiency. Ensure on-time service for a healthy compressed air system.
INVEST IN PRE-FILTERS
Not only do pre-filters (also known as coalescing filters) help purify air by removing oil and water but also particulate matter to a certain extent. Installing pre-filters for suction air and cooling air can extend the life of your compressor and its consumables.
Besides keeping your air clean, ensure that you give your compressed air system a thorough dusting every few months. Presence of sludge, dust or grime can have a big impact on the efficiency of the compressed air system. Pay special attention to compressor coolers and heat exchangers. Consider investing in a dedicated low pressure air compressor and air line for cleaning to save power.
PICK THE RIGHT DRYER
Selection of the right sized air dryer for your compressed air system is crucial. Make sure the energy consumption of the dryer is in proportion to the demand. An oversized dryer can add to your electricity bill significantly.
CONSIDER A VFD
Screw compressors should run under full load.
If the usage pattern varies, consider a Variable Frequency Drive (VFD) for upto 35% reduction in energy cost. A VFD helps regulate the energy consumption based on demand fluctuations, ensuring energy efficiency. ELGi’s VFD has helped clients realize up to 215% savings in maintenance and energy cost with payback as low as 7 months.
PERFORM QUARTERLY MAINTENANCE CHECKS
The importance of maintenance cannot be overemphasized.
Regular maintenance can help you identify and accurately measure leaks in the circuit. They also reduce the chances of breakdowns leading to maximum uptime and productivity.
PREVENT MISUSE OF AIR
Wasted air is wasted money. Invest time and money in training employees for efficient compressed air management. Create maintenance logs and update them on a regular basis, recording abnormalities or leaks in the systems. Systematically label leaks with proper tagging and prioritize repairs and plugging of leaks.
It’s common knowledge that heat is produced during the process of air compression. If not used judiciously, all the heat energy goes to waste. Over 90% of the heat produced can be recovered and utilized for heating air or water at the facility.
GET AN AIR AUDIT
Air audits enable companies to work with experts in the field and get valuable insights into their plant’s compressed air utilization. Michigan Air’s air audits provide a customized and comprehensive energy management plan to help you run more efficiently. Over the years, we have helped save millions of dollars in energy costs. Request an air audit now: mi-air.com/services/
If you need asistance or have additional questions, please contact us. We’re here to help!
Rotary Screw Compressor Troubleshooting Guide
Run more efficiently with this quick reference guide that covers issues such as:
- Low pressure
- Excessive vibration
- Low oil pressure
- Excessive oil consumption
- Excessive current draw
- Failure to start or motor stalls