Total systems approach

Understanding the total impact of running a compressed air system and identifying the necessary actions based on unique compressed air needs can reduce energy costs by as much as 20%.

 

 

While compressor technology is important, focusing on supply-side components alone will not likely deliver the desired cost savings or performance improvements. Factors such as undersized downstream equipment, wasted air and leaks can reduce potential savings and performance along the way.

It’s essential to know how to run a compressor room, but additional factors, such as system air pressure and flow, heat recovery, air quality issues at point-of-use, and wasted air also need assessment to effectively impact system performance, energy use, and cost savings.      

Even in cases where a system appears to be running well, it’s likely that somewhere along the line costly compressed air is being wasted. Taking a total systems approach, including a complete analysis of both the supply and demand sides of your system, is the only way to ensure constant and steady system pressure, uninterrupted workflow and minimal downtime. A total systems approach also is central to understanding your total cost of ownership.

Here’s an overview of some key considerations: 

Supply

•  Excessive pressure drop through filters, dryers, inadequately-sized piping. 

•  Air loss through timed condensate drains, cracked valves, leaks at connections or instrumentation.

•  Inefficient control scheme such as modulating valves or load/unload with short cycling.

 

 

Constituents of demand

•  Air events where specific applications create large swings in demand.

•  Leaks in transmission and point-of-use.

•  Inappropriate uses of air such as  venturi vacuum or open blowing for cooling or drying.

•  Inefficient consumption equipment analysis, especially multiple regulation devices. 

•  Flow restrictions or undersized hose at point-of-use.

•  Rate of change in a facility’s overall demand profile.

 

 

The high cost of air—what’s the real story? 

A compressed air system is a significant investment for any operation and requires disciplined maintenance to ensure maximum performance, payback, and system longevity. 

For example, the initial cost of a 100hp compressor with air treatment can cost up to $100,000 with installation. Following the initial investment, a facility can expect to spend between ten and 30% of its total electric costs to generate compressed air, and as much as 10% of the initial system cost on annual maintenance. Compressed air systems are also notorious for inefficiencies and leaks that, on average, waste from 30 to 50% of compressed air. 

Yet in the majority of cases, the idea of 'total cost of ownership' is trumped by the initial equipment and installation investment cost on paper. 

You can’t accurately determine savings without looking at the entire system, part by part, and how each element works together. This includes supply-side components such as compressor controls, air-treatment equipment, dryers and filters as well as demand-side equipment which includes heat-recovery and point-of-use systems. How air system components work together to produce air and exactly what’s happening throughout that process to configure, calibrate and maintain optimal performance is what a total systems approach is all about.

Advances in compressor technology are making total system expertise essential, as many companies look to their equipment provider for specialized know-how and component expertise. In addition, advanced analytics are now available to help determine the right equipment configurations throughout the system in order to optimize performance.

 

 

Know your options

Working with a compressor provider who understands the demand and supply sides of your compressed air system can help.  

When equipment providers and end-users come together with a shared focus on maximising the total cost of ownership, it’s possible to turn the liabilities of an inefficient system into a performance advantage. Implementing total systems programs help companies improve the energy efficiency and performance of compressed air systems.