The truth is that it is always “all of the above,” plus others.
The truth is that it is always “all of the above,” plus others.
The survey must provide a quality overview of the compressed air system at a cost commensurate with the system size, complexity, and potential recovery. The survey should generate both short- and long-term plans to establish basic control and management of the air system.
Focus on what is needed to pull together the interrelated parts of the system, and allow the user to understand the “basics” of these parts and their relationship. Create a general guide you can follow to continue to increase the efficiency of the system. Identify specific programs and actions to be implemented with estimated costs and payback. Develop a full sustainability program to include basic plans for expansion if required.
Certainly, this minimum effort should not be expected to produce the ultimate payback associated with more complete and detailed system analysis and training. The initial audit should lead to additional follow-up programs, or even to completely controlled and fully managed compressed air systems. The well-thought-out, simple audit has its place. It can generate significant savings, a success that should lead the user to more in-depth programs in the future press for efficiency and returns. Audits that do not contain this should be deemed unacceptable.
The demand side is another case altogether. Identifying and implementing energy-saving projects are always very significant. Continuous and diligent monitoring and review is essential to retain sustainability.
The actual projects will ultimately dwarf the supply-side savings over time. Many of the generic areas for energy savings continue to create new significant opportunities in the future as technology (particularly electronic) continues to improve. Many processes, such as blow-off efficiency, air-driven vacuum generators, cabinet cooling, and diaphragm pump controls, continue to evolve with new energy-saving designs and controls. All processes should be reviewed every two to three years.
We often classify waste management and demand-side management as separate sectors, but they are, in reality, two parts of the same entity. Together they generate the air usage for which the compressors supply air. You should look at waste management separately, because it is obvious yet often ignored.
Everyone always jumps immediately to leaks, and they should and must be addressed. It takes proper equipment in the hands of trained personnel accurately evaluating leak size and measured system performance to identify the true recovery value in electric energy dollars for their repair and elimination. For example, a 1/4-inch air leak could be equal to the cost equivalent of operating about 286 light bulbs at 60 watts each.
Air systems have a supply side and a demand side. For optimum performance, we want the supply-side compressors to produce and store air at the highest necessary pressure. On the demand side, we want to run at the lowest effective pressure at each process. A good compressed air management program looks at the entire system. It recognizes interconnectivity to optimize compressed air energy cost to the corresponding productivity. Any program that does not deal with these areas on a continuing basis will not be effective nor have any permanent positive effects.
One of the most important components of any compressed air program is employee education and awareness. Every employee, from management to machine operators, should be made aware of the costs of air usage and waste. Company newsletters should include a column on air use. Employees should be encouraged to report air leaks. Machine operators must remember to turn off the air supply to idled equipment and to report any air-related problems.
Employee recognition is essential. Appreciation of those employees who have contributed to air loss prevention will go a long way to encourage others to participate. This can come from mention in a newsletter, a public announcement, or even by a plaque or notice on the company bulletin board.
Compressed air is not free, but it can be less expensive and more reliable with a proper systems analysis review and management program. Learning to manage and maintain your compressed air system now will save you time and money in the future.
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