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How to Save Money and Energy by Making These Simple Changes to Your Compressed Air System

September, 2020

It is no secret that compressed air is an expensive resource. In a typical industrial environment, the electric power spent energizing air compressors represents 15 to 30% of all energy consumed by a given facility. While there are several ways to reduce the demand for compressed air within a facility, enacting such methods are difficult to accomplish without the ability to accurately monitor a compressed air system. The FD-G Series provides a seamless way to gather air consumption data as well as analyze trends to make informed decisions towards a more cost effective compressed air system.


1 Calculate Necessary System Pressure

A higher discharge pressure from the compressor correlates to a larger energy cost to run the compressor. Review the pressure necessary for each machine to run properly and compare it to the actual discharge pressure read using a pressure gauge. Simply lowering the discharge pressure by 2 psi can save you a substantial amount of money on your next energy bill. A discharge pressure well above the system requirements are signs of large pressure drops due to leaks, dirty filters, artificial air use, etc.

2 Prioritize Leaks

On average about 25-30% of all the compressed air produced by the air compressors never has the opportunity to be used by the machine. Leaks are inevitable, however the FD-G provides the ability to quantify those leaks. By quantifying leaks, it is easier to prioritize the largest leaks first that can lead to the largest savings. As mentioned above, leaks are one of the main catalysts requiring a higher discharge system pressure. Fixing your largest leaks first provides the opportunity to lower the system discharge pressure and in turn provide savings as well. In addition, after fixing identified leaks, it is easy to monitor a reduction in air lost and perform maintenance only when necessary.

3 Optimize the Compressor Schedule

There are several factors that hike up a facilities energy bill. Many factors are often over looked due to a lack of understanding of how ones compressed air system operates. To truly be able to optimize a compressed air system for energy savings, one must monitor their usage at all times.

For example, the largest consumption of energy dollars related to energizing a compressor occurs when the compressor is being powered ON or entering the loading state. One way to decrease these occurrences is by modifying the pressure point at which the receiver/storage tank is triggered to enter the loading state. (Reference image below) As a given facility uses stored compressed air, the receiver/storage tank pressure starts to drop. Once tank pressure reaches a set pressure threshold the tank will trigger for a compressor to enter the loading state and fill the tank to max pressure. By bringing down the tank pressure, the compressor will inadvertently enter the loading state less frequently and substantial savings as well as reduced compressor wear can be realized.

However, to make such adjustments to the compressor schedule, you must first monitor when the compressor is turning ON and OFF and at what percent capacity is that compressor running. After gathering your compressed air baseline information, you will be able to start asking questions like: "Am I able to turn OFF one my compressors during the 2nd shift?" or "Can I decrease the pressure threshold of my storage/receiver tank?" and start saving money on your next energy bill.

In a time where discovering ways to increase profit margins has never been more important, the FD-G provides the stepping stones to accomplish these goals.