Tag: optimize compressor controls

Optimization:  Step 6 – Control the air pressure

Published on by johnball2014Leave a comment

Since air compressors use a lot of electricity to make compressed air, it is important that you use it as efficiently as possible.  EXAIR generated a chart with six simple steps to optimize your compressed air system.  Following these steps will help you to cut overhead costs and improve your bottom line.  In this blog, I will cover the sixth step; controlling the air pressure at the point of use.

Pressure Regulators

One of the most common pressure control devices is called the Regulator.  It is designed to reduce the downstream pressure that is supplying your system.  Regulators are commonly used in many types of applications.  You see them attached to propane tanks, gas cylinders, and of course, compressed air lines.  Properly sized, regulators can flow the required amount of gas at a regulated pressure for safety and cost savings.

EXAIR designs and manufactures compressed air products to be safe, effective, and efficient.  By replacing your “old types” of blowing devices with EXAIR products, it will save you much compressed air, which in turn saves you money.  But, why stop there?  You can optimize your compressed air system even more by assessing the air pressure at the point-of-use.  For optimization, using the least amount of air pressure to “do the job” can be very beneficial and practical.

Model 1100

Why are regulators important for compressed air systems?  Because it gives you the control to set the operating pressure.  For many blow-off applications, people tend to overuse their compressed air.  This can create excessive waste, overwork your air compressor, and steal from other pneumatic processes.  By simply turning down the air pressure, less compressed air is used.  As an example, a model 1100 Super Air Nozzle uses 14 SCFM of compressed air at 80 PSIG (5.5 bar).  If you only need 50 PSIG (3.4 bar) to satisfy the blow-off requirement, then the air flow for the model 1100 drops to 9.5 SCFM.  You are now able to add that 4.5 SCFM back into the compressed air system. And, if you have many blow-off devices, you can see how this can really add up.

In following the “EXAIR Six Steps To Optimizing Your Compressed Air System”, you can reduce your energy consumption, improve pneumatic efficiencies, and save yourself money.  I explained one of the six steps in this blog by controlling the air pressure at the point of use.  Just as a note, by reducing the pressure from 100 PSIG (7 bar) to 80 PSIG (5.5 bar), it will cut your energy usage by almost 20%.  If you would like to review the details of any of the six steps, you can contact an Application Engineer at EXAIR.  We will be happy to help. 

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

Compressor Controls – Maximize Supply Side Efficiency

Published on by Tyler DanielLeave a comment

Air Compressor
Air Compressor and Storage Tanks

One of the most important aspect of an efficient compressed air delivery system is effective utilization of compressor controls. The proper use of compressor controls is critical to any efficient compressor system operation. In order to reduce operating costs, compressor controls strategies need to be developed starting with minimizing the discharge pressure. This should be set as low as possible to keep energy costs to a minimum.

The compressor system is designed with maximum air demand in mind. During periods of lower demand compressor controls are used to coordinate a reduction in output that matches the demand. There are six primary types of individual compressor controls:

  1. Start/Stop – This is the most basic control. The start/stop function will turn off the motor in response to a pressure signal.
  2. Load/Unload – The motor will run continuously, but the compressor unloads when a set pressure is reached. The compressor will then reload at a specified minimum pressure setting.
  3. Modulating – Restricts the air coming into the compressor to reduce compressor output to a specified minimum. This is also known as throttling or capacity control.
  4. Dual/Auto Dual – On small reciprocating compressors, this control allows the selection of either Start/Stop or Load/Unload.
  5. Variable Displacement – Gradually reduces the compressor displacement without reducing inlet pressure.
  6. Variable Speed – Controls the compressor capacity by adjusting the speed of the electric motor.

Most compressor systems are comprised of multiple compressors delivering air to a common header. In these types of installations, more sophisticated controls are required to orchestrate the compressor operation. Network controls link together each compressor in the system to form a chain. Usually, one compressor will assume the lead role with the others taking commands from the primary compressor. Some disadvantages of network controls include: only having the ability to control the compressors, cannot be networked with remote compressor rooms without a master control, and they generally only work well with compressors of the same brand due to microprocessor compatibility issues.

In more complicated systems, master controls can be used to coordinate all of the necessary functions to optimize the compressor system. Master controls have the ability to monitor and control all of the components within the system. The high-end master control systems utilize single point control logic with rate of change dynamic analysis in order to determine how the system will respond to changes. Changes on the demand side, supply side, or the ambient environment will all impact a compressor’s performance. An effective master control will be able to identify these changes and provide the most energy efficient response.

At the point of use, it’s always important to ensure you’re using a product that was engineered to reduce compressed air consumption. EXAIR’s line of Intelligent Compressed Air Products are available from stock to help you manage your overall operating costs.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

Images courtesy of thomasjackson1345 via Creative Commons License.