System Assessments

DENSO Compressed Air Leak Detection Program Drives CO2 Reduction Results

By Mike Grennier, Compressed Air Best Practices® Magazine

Given that compressed air leak management programs are meant to save energy, reduce CO₂ emissions, and generate ROI, DENSO’s Maryville, Tennessee, manufacturing facility can definitively say it has scored a trifecta when it comes to results – and reaped benefits beyond hard numbers alone.

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How IoT and AI Transform Compressed Air System Management

By Jayme Leonard, Atlas Copco Compressors

In the rapidly evolving landscape of industrial automation, the integration of internet of things (IoT) and artificial intelligence (AI) is reshaping production and utility management. Compressed air system management stands out as an area undergoing significant transformation. Compressed air systems are critical in many industries, serving as a power source for tools, machinery and various processes.

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Hitting the Gas on Efficient Compressed Air Delivery at Hitachi Astemo

By Compressed Air Best Practices® Magazine

Hitachi Astemo’s efficiency gains will turn into significant cost savings. In this article we outline the savings reported by the client since the changeover was complete. It shows a sizeable reduction in energy costs, air compressor energy costs and maintenance costs to the tune of 21.95%, 24.14% and 24.14%, respectively. Total operating costs to date have dropped from \$1,277,394 to \$941,959 with the new system a decrease of 26.25%.

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Plastic Pipe Selection in Industrial Compressed Air Applications

By Mark Gore, Business Development Manager, Asahi/America, Inc.

Compressed air piping systems contain high amounts of stored energy, which can be dangerous if released suddenly. Most plastic pipe systems are not suited for this application. The Occupational Safety and Health Administration (OSHA) has issued rulings regarding the use of thermoplastic piping materials for these applications.

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Four Compressed Air Demand Reduction Projects

By Don Van Ormer, Senior Auditor, APenergy

A large food manufacturing operation in the U.S. Midwest spends $529,000 annually on energy to operate the compressed air system. The plant currently has two supply-side systems that operate and feed two different distribution networks at two different pressures. One compressed air system is at 115 psig (medium pressure system) and the low-pressure system is at 30 psig. The compressed air equipment for both systems is located in four areas throughout the facility.

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Beyond Leaks—Factory Continues Reducing Compressed Air Demand

By Don Van Ormer, Senior Auditor, APenergy

A significant manufacturing operation, in the U.S. Midwest, had successfully deployed a compressed air leak management program. This on-going leak management program, along with tuning the air compressor control system, had delivered energy savings and a more reliable compressed air system.

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Improving the Efficiency of Pumping Systems through Pump System Optimization

By Matthew Derner, Manager, Business Development, Pump System Programs, The Hydraulic Institute

The U.S. Department of Energy’s 2002 Motor Market Assessment established that pumping systems offer the greatest optimization potential of all types of fluid systems, with potential savings up to 75% and an average net savings of 20.1%. In this article, The Hydraulic Institute defines the steps for a pump system optimization.

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Defining the Purity of Facility Generated Nitrogen Gas

By the Compressed Air & Gas Institute

While oxygen is unquestionably the most important gas in our atmosphere, as it is essential for most animals and human life, nitrogen is the most widely used atmospheric gas. Nitrogen is the go-to gas for countless industrial, medical, and scientific applications. This is because nitrogen is in vast supply, inert, and possesses the desirable characteristics of being colorless, odorless, and tasteless. The purity of nitrogen significantly affects the outcome of the application for which it is used and how the industry measures the purity of nitrogen gas is the focus of this article.

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Improve Process Efficiency and Reduce Energy Use with Compressed Air Monitoring

By Hendrik Priemer, Product Manager IIoT Applications, Machine Automation, Emerson

Without compressed air monitoring, up to 30% of the compressed air generated goes to waste. This waste occurs for several reasons, including leaks caused by failures at joints and tubes, exposure to vibration and normal component wear, and the suboptimization of machines and devices. Continuous monitoring capabilities allow operators to detect leaks and other anomalies in their early stages. By addressing pneumatic issues before they can grow, companies can reduce compressed air use by 20% to 30%.

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Using Air Storage to Balance Capacity in a Reciprocating Air Compressor Installation

By the Compressed Air & Gas Institute

One of the components frequently included in a reciprocating air compressor is an air receiver, often referred to as an air tank. Proper air storage is a critical component of intermittent duty cycle because for brief moments, the system can provide more compressed air than would otherwise be provided by the compressor pump. The capacity of compressed air piping also contributes to the total capacity of the air storage system.

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The Myth of Leak Repairs

By Tyler Costa, ALD Compressed Air Energy Solutions

When fundamentals like leak detection are neglected, best practices begin to slip. Inefficiency does not happen instantaneously, but slowly becomes the new norm as leaks or open blows are overlooked. Maintaining peak compressed air system efficiency is essential to streamlined operations. Better yet: it doesn’t need to be complicated. A clear, concise, and actionable plan will prevent negligence and keep your operation up-to-date on energy efficiency and cost savings.

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