Wednesday, 27 February 2013
High energy costs and increased environmental consciousness have put industries under immense pressure to find ways to maximise energy efficiency. One area in which companies are looking to reduce power consumption is in the operation of compressed air systems. Studies have found that inefficiencies in compressed air systems contribute to, on average, more than 30 percent in additional energy consumption! A compressed air audit is a cost-effective process that helps to identify inefficiencies, maintenance issues, and areas of potential savings in industrial compressed air units.
A compressed air audit is performed in three major ways:
1. Visual inspection
2. Data logging
3. Air audit
As the name suggests, visual inspection involves a thorough visual check of the entire compressed air system. It's the simplest of all compressed air audit procedures, and it does not involve the use of any hardware. During the audit process, inspectors may check and analyse things like the piping structure, filters, dryers, and condensate drains.
A visual check can help identify many of the issues that affect the compressed air system's overall performance, including leaks, improper piping design, faulty compressor, and more. It can also be very handy in providing a brief assessment of the existing productivity levels, nature of the system's components and determining the changes that could be undertaken in order to maximise efficiency.
This is a more advanced procedure that involves the use of data loggers and modern computer-aided processes to analyse the performance of a compressed air system. This procedure allows the system's performance to be monitored without the need to interfere with its air distribution network. All necessary data required to ascertain the efficiency of the compressed air system is gathered using data loggers. Then it's transferred into a computer, whereupon a system-specific performance profile is created.
The profile helps to identify things like idling performance, air demand fluctuations, compressor operation, and power allocation and compressed air demand in each compressor. Computer programs may also be used to evaluate the data and simulate alternative systems for comparison purposes. This helps to identify the modernization measures, such as replacement of some components or new configurations, which may have to be undertaken in order to improve the system.
Some compressed air audit firms use data logging of the electricity current (Amps), and then use a standard formula that includes a power factor to determine the value of kW. Graphs illustrating demand may also be included.
Air audits involve the taking of specific measurements, such as power and flow rate, leak detection, etc. During the audit process, air measurements are typically undertaken over a 7-day cycle to determine the exact compressed air demand of a plant. This helps identify energy costs, and areas of potential savings. Again, this procedure can be carried out without interrupting the air distribution network.
Air leak detection is done to give an accurate account of any existing air leaks. Research has shown that air leaks are responsible for up to 20 percent of compressed air system demand. You can imagine the kind of savings you can make by identifying and rectifying leaks on your facility's system.
An air quality audit checks if there's any oil or water in the compressed air. Apart from contributing to the frequent and costly filter cartridge changes, dirty air can cause work interruptions or stoppages.
With all these benefits, any money you may spend on compressed air audit is worth every penny. So don't be hesitant to spend money on it. You'll not only lower your energy costs, but your production lines will operate in a more efficient manner as well.
Thursday, 21 February 2013
The household and industrial uses of vacuum pumps and systems are diverse. The vacuum systems need proper care to guarantee efficiency in energy consumption and mechanical operation. Several companies provide vacuum management services to assist others in fulfilling their efficiency goals. When reaching out to benefit from these services an organization can chose a number of ways to finance the cost of management.
Proper functioning vacuum systems are mandatory in industries such as chemical and pharmaceuticals. Unfortunately, the use of the vacuum system yields large amounts of hazardous waste. The cost of dealing with the waste can be exorbitant. It is better to work on the efficiency of the vacuum system to minimize the waste and save not only energy costs but also waste management costs.
An organization can always benefit from external vacuum management services even if it has a well-funded internal team to provide the same. One benefit of going with a different company is that it lacks stakes in the client organization and will therefore provide accurate and unbiased results and recommendations. The second thing is that in most cases people who are already used to working with the current systems will rarely notice any deterioration. It takes a trained person from outside the organization to pin point the existing problems.
Cost Savings with Vacuum Management Services
Common vacuum management services that companies can contract from outside include auditing of vacuum systems, consultancy on continual improvement of the same systems, training of personnel to handle the system and advice on how to design and build new systems. If a company relies on non-renewable energy sources to power its operations then any additional power demand places the firm in a conflict relationship with environmental management authorities. Such a company stands to benefit the most from vacuum management services.
The service provider often works with relevant partners and authorities. In some cases, the client company can qualify for audit funding from several environment management funds. A competed service provider will be able to advice the client company on the right procedure of funding the services using the aid money.
The most critical stage of management comes after the audit. Companies need a helping hand in implementing changes to achieve new efficiency levels in their systems. They also need assistance to maintain the high efficiency standards. System dynamics always change and some situations will warrant the addition or removal of certain equipment that act as components of the system. The company will need support on developing continuity despite the changes.
For a company to run a vacuum system it has to have qualified staff. Hiring competent staff is the basic thing that the company can do, but to guarantee that its systems remain efficient, the company must consider exposing the staff to system awareness training periodically. Arrangements are always possible for different employee classes.
It is almost impossible to run a chemical or pharmaceutical manufacturing and processing business without installing vacuum systems to aid chemical reaction and distillation processes. Several other industries also depend on vacuum systems. Unfortunately, many companies are passing on huge cost related benefits because they fail to take up vacuum management services. Do not let your company wait any longer, contact a provider now and start enjoying the cost savings.
Call Air Compression Technology for more details, 01142 308070.
Thursday, 7 February 2013
A compressed air audit is one of the best steps that you can take if you are looking for an opportunity to save energy costs. The compressed air audits that we carry out can help to find probable causes of misuse and wastage and then we can propose the ways in which the problems can be solved. Visit us online to find out about our compressed air audit and other compressed air services.