One hidden problem in many compressed air systems is something called “artificial demand.” Many users are unaware of the effects of this component of compressed air demand as evidenced by higher than needed compressed air pressures on most systems. Artificial demand in a compressed air system refers to the excess consumption of compressed air caused […]
Compressed air fail: Expensive air conditioning
Compressed air is useful for very many important tasks in facilities. However, due to the high cost of producing it, there are some end uses that are very wasteful. Air conditioning and ventilation is one such inappropriate end use. In a recent survey, a compressed air auditor found a surprisingly unique waste of compressed air […]
Compressed air fail: Corrupted VSD settings
When the equipment is new and set up correctly, the coordination of VSD air compressors with fixed speed units is quite easy — if the number of compressors in the mix is four or less. Typically, what should happen is the VSD compressor maintains trim position with all combinations of fixed speed compressors providing base […]
Compressed air fail: Hidden filter
A compressed air audit at a metal parts painting plant yielded some puzzling results. Pressure loggers were placed at the compressor discharge and in the plant, but the readings were showing an unexpected and significant pressure drop between the instruments. Visual checks showed that the only thing between the loggers was an air dryer with […]
How do you become a CAGI Certified CCASS?
By Ron Marshall You may have noticed some email signatures displaying the Certified CCASS symbol — and have become curious as to how that’s earned. Anyone, if properly prepared, can become certified by writing and passing an exam. The ease in preparing for the CAGI (Compressed Air and Gas Institute) Certified Compressed Air System Specialist […]
Compressed air fail: Dryer balance
A compressed air auditor was monitoring a system in a plant that produces plastic film. Part of the measurement involved analyzing the flow from the compressor room and the dewpoint of the compressed air. When examining the data, a strange pattern developed on the flow and dewpoint profiles (Fig. 1). We can see the output […]
One Cajun beef, please, but hold the air compressor oil
No one wants air compressor oil contaminating production. And in food processing applications, quality and safety are essential. E2M Kitchen, a fresh and ready-to-eat meal provider, knows this all too well. The Charlotte-based company significantly evolved its food preparation and packaging process for creating gluten-free, dairy-free, and preservative-free meals. Every tool used in its production […]
Sauer Compressors announces two new managing directors
Two new managing directors strengthen the management team of the Sauer Compressors Group. The compressor manufacturer has appointed Nicole Fässler as CFO and Mladen Milcinovic as COO as of January 1. As CFO, business economist Nicole Fässler is responsible for the new management area of Finance, HR and IT. The Swiss national has extensive experience […]
Compressed air fail: Unexpected water
It’s always frustrating to find water in a compressed air system, and especially so in locations where the air is supposed to be dry. During a recent compressed air audit, a survey of the piping found that poor dewpoints were being experienced in the system. Investigation found that significant amounts of free water mixed with […]
Compressed air fail: Extra heat
Most of the energy that goes into an air compressor comes out as heat, so it is always a good idea to direct the hot air produced to a location that needs heat — like into a plant in the winter season. The compressor in the photograph has a specially designed heat recovery system that […]
Compressed air fail: Bad water
Water-cooled compressors can have an advantage in locations where the ambient conditions are hot — and therefore using air cooled compressors would result in discharge temperatures that exceed the capacity of the air-drying systems. Overloading air dryers could result in free water entering the plant piping system. This would cause contamination of connected machines and […]
Compressed air fail: A rat’s nest of wiring
An air compressor at a metal processing plant had a troubled life. It started out as a VSD controlled machine, but a fire damaged the controls. Because of this, a new VSD was installed. It didn’t match the old drive, so wiring was altered to accommodate. Next, the drive failed due to dust contamination and […]
High-pressure oil-free compression technology now part of Atlas Copco Group
Hycomp Inc.’s technology has become part of Atlas Copco Group. The company designs, produces, sells and services specialized high-pressure oil-free compressors and boosters for a variety of industries. This is the second such acquisition by Altas Copco, which announced the acquisition of industrial gear pump manufacturer Kracht on January 3. Hycomp is a privately owned […]
Compressed air fail: Quadruple dry
A metal processing company had a laser cutter installed in its manufacturing plant to produce accurately fashioned pieces from metal sheets. This machine requires compressed air that is dried to about 35° F for general use but requires a small amount of air to keep the beam path clean —this avoids contaminating the expensive positioning […]
What is a lubricated compressor banana curve?
If you are carefully selecting your new compressors by looking at Compressed Air & Gas (CAGI) data sheets, you should be commended. Use of these sheets are a great way to compare compressor energy and flow characteristics between brands of compressors. In this way, you can choose the most efficient machine for your use and […]
Compressed air fail: Small compressor
A power utility had a 100-psi station service compressed air system that was used infrequently for maintenance. Two 50-hp water-cooled compressors were installed to maintain system pressure during the high flows, but these were overkill for normal times when the compressed air flow was only about 10 cfm. To reduce the number of starts and […]
Compressed air fail: desiccant dryer with too much purge
An industrial compressed air user was having a difficult time with their high pressure compressed air system. The compressed air demand required instrument quality air, so a heatless desiccant air dryer was installed. The dryer uses activated alumina within its chambers to strip off the moisture from the compressed air flow using an adsorption process […]
Compressed air fail: Auto mode was forgotten
One little button click can save thousands of dollars in wasted electrical and maintenance costs on air compressors. Recently, a compressed air auditor encountered the same problem in two different plants; operators had failed to select “Auto Mode” on their compressors. Both units were 150-hp lubricated screw compressor installed in a system of multiple compressors. […]
Precise and localized pneumatics complement advanced motion controls in packaging machines
Packaging machine manufacturer Coesia and its sister companies rely on system integration for efficient, precise and fast operations. With a focus on streamlined systems that reduce pouch or carton handoffs and offer the ability to move non-standard sized materials, Coesia companies R.A. Jones and MGS turn to modern motion control systems married with precision pneumatics […]
Compressed air fail: Dew point bump
A compressed air auditor was hired to have a close look at the main compressed air system at a farm implement manufacturing plant. Data collection instruments were placed on the system to measure pressure, flow, and power. The auditor also placed a dewpoint meter at the discharge of the compressor room, after the main air […]
Compressed air fail: Here’s a record you don’t want to break
One important item discussed in Compressed Air Challenge’s Fundamentals of Compressed Air Systems seminars is leakage. The most common waste category is compressed air. When studies are done looking at leakage rates compared to the total amount of compressed air produced, on average somewhere between 20% and 30% is found at manufacturing facilities (Fig. 1). […]
How can you reduce air leaks without turning a wrench?
What if you could reduce all your leaks without turning a wrench? Well, it is possible with good pressure control. And sometimes it is as easy as turning a knob. The principle is shown in the following orifice chart, Fig. 1. As the pressure to a leak reduces by 1 psi, the flow consumed by […]
Helix connected platform provides real-time insights for compressed air systems
Ingersoll Rand announces the launch of its Helix Connected Platform, which provides valuable insights on compressed air systems to ensure reliability and extend equipment life. Developed for industrial applications to maximize uptime and peace of mind, the Helix Connected Platform provides continuous, real-time data monitoring for compressed air systems to enable maximum operational uptime. Advanced […]
Compressed air fail: Dead PFCs
One of many energy conservation measures available to industrial users is the use of pressure/flow control regulators. These are installed in systems to reduce the plant pressure while leaving the air compressors to operate within a wide pressure band, making them more efficient. A compressed air pressure/flow controller is a device used to regulate and […]
Kaishan USA launches industrial, oil-free rotary screw compressor
Kaishan USA has introduced a new series of industrial, oil-free rotary screw air compressors, the KROF. Plant managers and operators seeking to stay ahead of the ever-changing innovation that supports the food and beverage industry will find unrivaled value in the technical depth of the KROF. The KROF is a two-stage oil-free rotary screw air […]