Many ask “what is the secret to improving a compressed air system”. My answer is “measurement”.
The old phrase “you can’t manage what you don’t measure” is as true with compressed air as with any other important system in an industrial plant. And it is rare indeed to see a full set of measurement instruments installed on any compressed air system.
Correctly measuring your system is as simple as installing a complete set of adequate measurement instruments to measure pressure, power, flow and dew point. You don’t even have to do it, many service companies offer this service. Once done the analysis of key system indicators that are calculated from these readings can show you your problems and lead you down the path to improvement.
For example, a set of data for a two compressor 2 x 100 hp system running at 100 psi shows an average consumption of 150 kW while producing an average of 500 cfm. A quick calculation shows the specific power of the system at 30 kW per 100 cfm. If we know that an optimized system specific power should be about 18 kW per 100 cfm we know we have efficiency problems.
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These two indicators show us we have work to do.
This measurement and analysis process is called “baselining” and is a key part of any improvement to your system.
If you are interested in more information about baselining consider attending Compressed Air Challenge Fundamentals training. A calendar of trainings appears here. Be sure to check the calendar as more training will be added throughout the year.