Compressed air management claims big savings
An
Energair Solutions product story
Edited by the Engineeringtalk editorial team
Apr 8, 2004
Energair reckons a purpose-built control and monitoring system can manage existing compressed air installations more effectively.
Industrial companies spend on average 10% of their total electricity bill on compressed air generation.
A compressor installation that is 20% more efficient can therefore contribute a significant amount of money to the profits of most manufacturing companies.
Energair claims to deliver this gain in efficiency by using a purpose-built control and monitoring system to manage existing compressed air installations more effectively.
The claim is supported by good evidence as Energair compressed air management systems are installed in over 1000 manufacturing sites mainly in the UK, they range from major car manufacturers such as Peugeot, GM and Ford, to pharmaceutical giants GlaxoSmithKline and include many smaller local enterprises.
Energair reckons that industrial sites with even modest consumption can expect to save thousands of pounds, rising to tens of thousands for high volume, multiple compressor installations.
Payback periods typically range from six to 18 months depending on the size of the installation and the operating schedule; most large installations tend to run 24h and show shorter payback periods.
An Energair compressed air management system reduces compressor energy consumption by closely matching system pressure to demand and reducing offload running or idling of compressors.
The control is implemented in a number of ways depending on the installation.
A basic arrangement uses an Enercon system controller to ensure that all compressors on any one ring main, regardless of their make, type or capacity, operate more efficiently and contribute to savings.
More advanced systems use Energair software to provide live monitoring and information feedback, which can show aspects of equipment status and system pressure on-screen.
The display parameters include accurate metering of power consumption in kilowatt-hours, air production volume in cubic metres and efficiency in kilowatts per cubic metre.
The software also has a built-in reporting feature that can be used to produce regular performance reports allowing customers to closely track performance and use the information for internal management reports.
An additional proactive level of functionality is also available from the Energair system; an automated warning service that can be triggered by efficiency drops, poor equipment performance and even compressor bearing condition.
Multilayer responses are available locally via screen warnings and audible signals.
Remote warnings using a permanent mobile or landline phone connection can also be programmed to alert maintenance personnel or maintenance service providers with pre-emptive phone calls, faxes and text messages warning of problems, emergencies and routine maintenance checks.
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