Although the largest proportion of compressed air cost of ownership is the energy costs, a thorough maintenance regime will contribute significantly to overall system efficiency, helping to lower operating costs further.

To ensure the compressed air system optimises energy performance, it is important to maintain it regularly, in accordance with the manufacturer’s recommended service intervals. Poor equipment performance can place strain on components, which can lead to an increase in energy consumption.

Rather than waiting for a machine breakdown before action is taken, regular maintenance helps optimise compressed air system efficiency. This will avoid energy losses because of poorly performing equipment as well as unplanned outages and downtime.

Location, location, location

Compressors should always be located in a dry, clean, cool and well-ventilated area.  It takes more energy to compress warm air, yet some compressor plant rooms can run at temperatures as high as 30°C. This can cause more frequent breakdowns as well as wasting energy.

Installing extra ventilation, will help to keep the compressor room as near to ambient temperature as possible, placing less strain on the compressor and contributing to better performance.

Think system first

A compressed air system is just that – a system – and each component part needs to be maintained regularly to help maximise efficient performance.

Inspecting for air leaks in the compressed air pipework can pay dividends, as even the smallest leak can result in significant wasted energy and associated costs.

Just one 2mm hole in the pipework, could cost over £1,249 per year in wasted energy, so implementing a regime for regularly inspecting, and remedying can help lower operating costs. A high leak rate can also cause fluctuations in pressure, resulting in hidden costs such as slower running or even production downtime, not to mention a noisy environment for staff.

Inlet filters should also be checked routinely and replaced before the pressure drop across them becomes significant.

Finally, regular maintenance checks should extend to the entire system and encompass ancillary equipment, such as dryers, filters, air receivers and pipework.

Maintain to gain

Reactive maintenance was, for many years, the default option, where a compressor developed a fault and was subsequently repaired.  This could often lead to production downtime and the associated financial losses, so programmes were developed to introduce preventative maintenance regimes.

Now, operators can benefit from predictive monitoring and the opportunities that Industry 4.0, and increased data analytics can offer in maintaining their compressed air system.

Our BCAS members will maintain your compressors, downstream and ancillary equipment to the highest quality standards, offering a choice of planned, proactive or even predictive maintenance to keep your system running like clockwork.

Use genuine spare parts

Compressed air owners should always use genuine spare parts, rather than alternative options which may be available at a cheaper price.  Taking steps upfront to check the quality and suitability of the parts and components selected, can save significantly in terms of equipment failure costs, the associated downtime and energy consumption.

Genuine spare parts are designed specifically for the machine, so there is no danger of downgrading performance by installing components that are less than optimum.

Roy Brooks is technical development officer at the British Compressed Air Society (BCAS)

www.bcas.org.uk

Tel: 020 7935 2464