Intelligent Compressed Air®: Common Compressor Room Mistakes, And How To Avoid Them

While we don’t sell, install, or service air compressors, EXAIR Intelligent Compressed Air Products run on compressed air, so helping you get the most out of your compressed air system is important to us. Today, we’re starting where it all begins: the compressor room.

Some of the mistakes that are commonly made in the compressor room are by design, and others are operational. My colleague Tyler Daniel wrote a great blog on design considerations recently, so I’m going to focus on the operational aspects, which include maintenance…and maybe some minor design stuff:

  • Poor ventilation: Air compressors get hot. They’ve got a lot of moving parts, and many of those parts are moving under a great amount of force (pressure is literally defined as force per unit area), and at a high rate of speed. Add in the heat of compression (it takes energy to compress air, and that energy has to go somewhere, something another colleague, John Ball, explains here), to all that friction and you come up with a TREMENDOUS amount of heat. An industry thumbrule, in fact, states that over 2500 Btu/hr of heat is generated, PER HORSEPOWER, by a typical industrial air compressor. If the compressor room isn’t big enough, you’ll need an exhaust fan capable of removing all that heat.
  • Lack of filtration: Take a good, full breath in through your nose, right now. Did you smell anything unpleasant or irritating? I hope not…clean air is a “must” for your lungs (and the rest of your body), and the same is true for your air compressor (and the rest of your compressed air system). Keeping up with the maintenance on the intake filter is literally “starting where it all begins”…from the 1st paragraph.
  • Not removing moisture: Water & water vapor will have an adverse effect on many components of your compressed air system: it’ll cause rust in iron pipes, damage the seals in air cylinders, motors, tools, etc., and if you use it for blow off or conveying, it’ll contaminate your product. We’ve writtenagain and again…about the importance of dryers, and which type might be best for you.
  • Tolerating leaks: The compressor room is loud, so leaks are going to be pretty big before you can hear them. And to add insult to injury, the vibration of a running compressor makes the compressor room a prime location for them to occur. Even one small leak that you couldn’t hear in a quieter area will cost you over $100 over the course of the year, and maybe only take minutes to fix. Good news is, even if you can’t hear them, they ALL make an ultrasonic signature, and we’ve got something for that.
EXAIR Model 9061 Ultrasonic Leak Detector “finds them all, big or small!”
  • Ignoring maintenance. If you don’t schedule planned maintenance, your equipment will schedule corrective maintenance for you…oftentimes at greater expense, and with no regard to your schedule.
    • Moving metal parts that make metal-to-metal contact (or that have very tight spacing tolerances) HAVE to be lubricated properly. If you run low on oil, or let it get dirty or emulsified, severe damage will follow. Keeping an eye on the oil level, and changing it (and the filter) at the manufacturer’s recommended intervals, is critical.
    • Emulsified or otherwise contaminated oil can damage seals, gaskets, and o-rings. That’s obviously a big problem for the compressor, and when it carries over into the header, it’s a big problem for pneumatic cylinders & tools as well. Periodic sampling & analysis of your oil can provide timely notice of issues that can be corrected before they become catastrophic failures.
    • Depending on the type of compressor, and its drive system, the manufacturer’s maintenance recommendations may also include:
      • Checking coupling or belt alignment of the drive.
      • Checking bolts for loosening due to vibration (a “necessary evil”, especially with reciprocating compressors).
      • Adjusting the pistons to maintain valve plate clearance.
      • Tightening or replacing the mounts & vibration pads.

If you’d like to find out more about how EXAIR Corporation can help you get the most out of your compressed air system, give me a call.

Russ Bowman, CCASS

Application Engineer
EXAIR Corporation
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Image courtesy of PEO ACWA Some rights reserved Creative Commons Attribution 2.0 Generic (CC BY 2.0)

The Basics of a Compressed Air Leak Detection Program

It is no surprise that compressed air can be a costly utility for industrial facilities. It can easily chip away at the bottom line finances if used carelessly and without planning. This is one of the leading reasons we have educated continuously on how to ensure this vital utility is used with safety and conservation in mind. If we have installed all engineered solutions at the point of use throughout a facility, there is still more to be saved. One of the easiest things to do with a utility system inside of a facility is to leave it unchecked and undocumented until something goes wrong. This does not have to be the scenario and in fact, starting a leak detection program in a facility can help to save up to 30% of the compressed air generated.

Leaks cost money!

That’s right, up to 30% of the compressed air being generated in an industrial facility can be exhausting out to ambient through leaks that run rampant throughout the facility. When the point of use production is still working fine, then these sorts of leaks go unnoticed. Another common occurrence goes something like this example: Maybe there is a leak bad enough to drop the packaging line pressure slightly, this may get fixed by bumping up a pressure regulator, production is back up and it is never thought of again. In all actuality this is affecting the production more and more with each leak.

The leaks add additional load onto the supply side. The compressor has to generate more air, the dryer needs to process more air, the auto drains dump more moisture, it all ads up to additional wear and tear also known as false load. All of this additional load on the system can add more maintenance which if left undone can result in system shut downs. One way to begin to eliminate this false load is to deploy a leak detection program. The steps are fairly easy.

Similar to our 6 Steps to Compressed Air Optimization, you start with a baseline of how much air the system is seeing and operating pressures. This begins the documentation process which is critical to the success of the program. Next, acquire an ultrasonic leak detector (ULD) and a layout of your compressed air system piping. Utilizing the ULD, test all compressed air piping along with equipment, and tag each leak that is detected. Next, begin to repair all of the tagged leaks and document the amount of compressed air savings with each repair. This again, is more documentation which leads to giving a quantitative value to the return on investment of the program. Lastly, schedule a follow up scan that recurs on a pre-determined basis to prevent the system from returning to it’s original leaky state.

EXAIR Ultrasonic Leak Detector

If you would like to discuss starting a leak detection program in your facility or have questions about the ULD or any point of use compressed air product, please reach out to an Application Engineer today.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Leaks and Why They Matter

Leaks can be discussed quite frequently around industrial environments. These can be refrigerant leaks, water leaks, gas leaks, even information leaks. All of these leaks have one thing in common, they all cost the company money in the end. I often think about several classic cartoons when I hear about leaks being fixed as they are found. They can become a little overwhelming like the “Squirrel” from the movie Ice Age 2.

1 – Ice Age 2 – Scrat – Mission Impossible

When it comes down to it, not many leaks create good results, that is why I want to take a second and educate on the costs your facility may be seeing from compressed air leaks. The leaks within an industrial environment can often account for up to 30% of the total compressed air generated.

So let’s take a look at that, the cost of compressed air is derived from the kWh cost the facility pays to the utility company. Here in the Midwest the average cost is around $0.08 / kWh. The equation to convert this to cost per cubic foot of compressed air is shown below. This formula assumes that the compressor generates four standard cubic feet of compressed air per horsepower of compressor. Again this is an industry acceptable assumption.

The size of a leak will determine how much compressed air is wasted, most of these leaks are not even to the audible range for the human ear which leads them to be undetected for long periods of time. A leak that is equivalent to a 1/16″ diameter orifice can result in an annual loss of more than $836.50 USD. While the scale of this number when compared to the annual revenue of a company may be small, the fact remains that this single leak would more than likely not be the only one. This isn’t the only way leaks will cost money though.

Leaks can also generate false demand which can result in pressure drops on a system. When the pressure on a production line drops this could result in unscheduled shutdowns. Often, when a pressure drop is observed the quick answer is to increase the header pressure which causes even more energy to be utilized and even more compressed air will be pushed out of these leaks. That increase in system pressure comes at a price as well. When increasing a system pressure by 2 psi the compressor will consume an additional percent of total input power. This again will hit the bottom line and result in lower efficiency of operation for the facility.

If you hear that distinct hiss of compressed air leaks when you are walking through your facility, or even if you don’t hear the his and you know that a leak detection action plan is not being practiced and want to find out the best ways to get one in place, contact us. We are always willing to help you determine how to lower the leaks in your facility as well as reduce the system pressure required to keep your lines up and running by implementing engineered solutions at the point of use.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

1 – Ice Age 2 – Mission Impossible Scrat – retrieve from YouTube – https://www.youtube.com/watch?v=S-HniegbnFs

 

Why Start a Leak Prevention Program?

All compressed air systems will have some amount of leakage. It is a good idea to set up a Leak Prevention Program.  Keeping the leakage losses to a minimum will save on compressed air generation costs, and reduce compressor operation time which can extend its life and lower maintenance costs.

The Compressed Air Challenge estimates an individual compressed air leak can cost thousands of dollars per year when using $0.07/kWh.

  • 1/16″ diameter hole in excess of $700/year
  • 1/8″ hole in excess of $2900/year
  • 1/4″ hole in excess of $11,735 per year

There are generally two types of leak prevention programs:

  • Leak Tag type programs
  • Seek-and-Repair type programs

Of the two types, the easiest would be the Seek-and-Repair method.  It involves finding leaks and then repairing them immediately. For the Leak Tag method, a leak is identified, tagged, and then logged for repair at the next opportune time.

A successful Leak Prevention Program consists of several important components:

  • Document your Starting Compressed Air Use – knowing the initial compressed air usage will allow for comparison after the program has been followed for measured improvement.
  • Establishment of initial leak loss – See this blog for more details.
  • Determine the cost of air leaks – One of the most important components of the program. The cost of leaks can be used to track the savings as well as promote the importance of the program. Also a tool to obtain the needed resources to perform the program.
  • Find the leaks – Leaks can be found using many methods.  Most common is the use of an Ultrasonic Leak Detector, like the EXAIR Model 9061.  See this blog for more details. An inexpensive handheld meter will locate a leak and indicate the size of the leak.

    Model 9061
    Model 9061
  • Record the leaks – Note the location and type, its size, and estimated cost. Leak tags can be used, but a master leak list is best.  Under Seek-and-Repair type, leaks should still be noted in order to track the number and effectiveness of the program.
  • Plan to repairs leaks – Make this a priority and prioritize the leaks. Typically fix the biggest leaks first, unless operations prevent access to these leaks until a suitable time.
  • Record the repairs – By putting a cost with each leak and keeping track of the total savings, it is possible to provide proof of the program effectiveness and garner additional support for keeping the program going. Also, it is possible to find trends and recurring problems that will need a more permanent solution.
  • Compare and publish results – Comparing the original baseline to the current system results will provide a measure of the effectiveness of the program and the calculate a cost savings. The results are to be shared with management to validate the program and ensure the program will continue.
  • Repeat As Needed – If the results are not satisfactory, perform the process again. Also, new leaks can develop, so a periodic review should be performed to achieve and maintain maximum system efficiency.

An effective compressed air system leak prevention and repair program is critical in sustaining the efficiency, reliability, and cost effectiveness of an compressed air system.

If you have questions about a Leak Prevention Program or any of the 16 different EXAIR Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

Jordan Shouse
Application Engineer
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