A metal process plant has two breathing air purifiers installed on site for the protection of its personnel. These units are installed to ensure hazardous Carbon Monoxide is kept out of breathing air. Recently, the two systems were evaluated by a compressed air auditor. When paint fumes or metal particles are in the ambient air […]
Should wet compressed air receiver tanks be outdoors?
During plant inspections, it is often noticed that compressed air receiver tanks are installed outdoors. This is done for a reason — and is a good idea, in many cases, because it benefits the operation of air drying and filtering equipment and produces better quality compressed air when hot summer days cause worst-case conditions. Here […]
Compressed air fail: Remote cooler install
A wood products company called in a compressed air auditor to have a look at its compressed air system. System reliability was poor, and the staff was having issues with the main compressor, a 200-hp air cooled screw compressor that carried most of the plant load. This compressor was rated at 100 psi, but recently […]
Compressed air fail: Vacuum pick-up
A metal products manufacturer had a production problem in one of its processing areas. The maintenance staff had increased the discharge pressure on their air compressors to help with the issue, but it seemed the problem would come back occasionally with no warning. Fig. 1 shows the problematic item, a vacuum pick-up crane. When the […]
How can you spot wasted compressed air?
In a noisy industrial expensive plant, air leaks are everywhere, but hard to detect because the ambient roar washes out the sound of air leaving your system. But strange as it may seem, sometimes you can see compressed air leaks, or more accurately, you can see the result of the air escaping! Fig. 1 […]
Compact, efficient and intelligent multi-stage ejector
piCompact 10X Smart is a compact, efficient, and intelligent ejector that enables you to take the next step in production control and ease of use. Based on COAX technology and integrated IO-Link technology, piCompact 10X Smart offers enhanced flexibility, quicker installation, and improved customization to fit your needs. Building on the air-driven, multistage ejector piCompact […]
Compressed air fail: Nozzles check
By Ron Marshall A metal parts company had dozens of media blasters installed in its production areas to clean its products for final processing. These blast cabinets were in constant use throughout their 16-hour production day and consumed a significant part of the peak compressed air demands. The staff found that they were running out […]
Rockwell Automation and CaseiZ help manufacturers reduce energy costs
Nearly every manufacturing facility uses compressed air. And all share the challenge of keeping compressed air systems running efficiently and reliably. Depending on the industry (e.g., automotive, consumer goods, mining, etc.), the compressed air system accounts for 10-50% of a plant’s energy usage and is as essential to uptime as electricity. But compressors are inherently […]
Why does my compressed air quality go down in summer?
Are you spending your summer struggling with the quality of your compressed air, with stinky, rusty water pouring out of your pipes? When it comes to air quality, the hot summer months are the most challenging time for most compressed air systems, and to avoid problems, you need to plan for the worst-case scenario. Typically, […]
Compressed air fail: You forgot one thing
A meat processing company air upgraded its compressed air system to increase capacity and reduce energy consumption. They installed large, premium efficiency VSD compressors, a smart compressor controller, efficient filters, large storage, and heated blower desiccant dryers connected with oversized compressor room piping — all in an effort to reduce pressure loss. The maintenance workers […]
Five excellent compressed air knowledge resources to know
These resources cover a range of topics, from system optimization to maintenance practices and measurement techniques. They can provide valuable guidance for improving the efficiency and performance of compressed air systems in various industrial settings. 1. “Improving Compressed Air System Performance: A Sourcebook for Industry” by the U.S. Department of Energy (DOE): This valuable sourcebook […]
Why is compressor lubricant important?
The lubricated screw air compressors are the most common type in the industrial environment, helping power critical operations in various sectors. Maintaining the quality of your compressor lubricant is very important if you want trouble-free operation. Let’s examine the significance of maintaining high lubricant quality for a lubricated screw air compressor — and its overall […]
How do you check your compressed air storage size?
A very important element of any compressed air system is the system storage volume. But how much do you need? Is your storage capacity big enough? Sufficient system storage is important to the efficiency of a compressed air system because it allows for easier compressor control. Having a large volume connected to your compressors slows […]
When is it time to retire an air compressor?
When is it time to retire a compressor? Your old unit may have served you very well over the last few decades, reliably providing a seemingly endless supply of compressed air. Some units, like the unit in Fig. 1, have been around so long that they have almost become part the family. This design is […]
Compressed air fail: OSHA blow gun regulations
Despite being in force since the early 1990s, compressed air auditors frequently run across compressed air safety hazards when studying their client’s sites. Fig. 1 is a common example where blow guns installed for cleaning have been modified by machine shop personnel. This gun, if the tip is blocked, will deliver over 100 psi to […]
How do you size your air receiver?
Compressed air receivers have become more important in modern compressed air systems. Having an adequately sized main receiver in the compressor room is quite important for the health and efficiency of your air compressors, especially if you have switched from small reciprocating compressors to lubricated screw type. Years ago, the rule of thumb for use […]
Tsunami CORE desiccant dryer available for pre-order with August launch
Tsunami CORE series desiccant dryer is the newest addition to the Air Dryers product line, designed to better serve the automotive and professional coatings industry. This manual change desiccant air dryer features a spring-loaded cartridge style desiccant canister that eliminates dusting and tunneling of the media. It is rated for 25 cfm and is designed […]
Compressed air success! Found gold
A wood products company decided to conduct a treasure hunt for energy savings on its compressed air system. Plant personnel were scheduled to have a production outage during a one-week period — and so they invited a compressed air expert to help them identify any suggested improvements to the system. Industrial plants frequently have staff […]
Elgi announces energy-saving dryers at the 2023 AICD conference
Elgi North America will introduce the AR Premium Series Energy Saving Cycling Refrigerated Air Dryers at the annual Association of Independent Compressor Distributors (AICD) conference in Grapevine, Texas, taking place from May 21–23. In addition, Elgi will showcase its expanded range of AB Series oil-free screw air compressors in 15-30 hp, offering a more affordable […]
Compressed air fail: Poor disposal
A lumber processor installed a remote lubricant-injected rotary screw compressor in an outbuilding to supply compressed air to a debarking system out in the yard. Lubricant injected air compressors normally pass some compressor oil into the system — usually about 4 parts per million for a well-maintained compressor — even though there is an air/oil […]
New dry rotary vane vacuum pumps from Atlas Copco
Atlas Copco has developed its new DVS vacuum pump series with a focus on this requirement profile. The result: the DVS models are oil-free, dry rotary vane pumps that guarantee emission-free, quiet operation and do not contaminate the processes. High efficiency at competitive costs “This makes them ideally suited for a wide range of applications, […]
Kaeser’s new active oil-water separator shown at Hannover Fair
With the intelligent Aquamat i.CF, Kaeser Kompressoren has redefined condensate treatment. Available for delivery volumes up to 90 m³/min, this new oil-water separator now comes equipped for the first time with the Aquamat Control internal controller, which undertakes active management of the process while simplifying maintenance planning and making service work cleaner. Wherever compressed air […]
Compressed air fail: Strange CFM profile
A sawmill maintenance department requested a compressed air assessment to determine the efficiency of its system and to find out if any improvements could be made to reduce their compressed air system operating costs. They called in an auditor who placed data logging equipment to measure pressure, flow, and power. From these measurements, the auditor […]
Rotary screw compressors more efficient than ever
Rotary screw compressors are the dependable backbone of an industrial compressed air supply. With a multitude of features, the innovative CSD/CSDX range from Kaeser Kompressoren fulfills this role more efficiently, dependably, and economically than ever before, while at the same time reducing a company’s CO² footprint. The most important highlight of these compressors is their […]
Compressed air fail: Air dryer robbery
A routine audit of a wood products company has turned up some surprising results on a system that was thought to be very efficient. The system is simple — one compressor, a 100-hp variable speed drive controlled (VSD) screw compressor, and a heatless desiccant air dryer. Data loggers were placed on the system by a […]