10 steps you should take to cost savings

Compressed air is a common utility found in most industrial facilities. In fact, it is often referred to as the “fourth utility,” along with electricity, wafer and gas. In many plants, the electrical power cost for operating air compressors and air treatment equipment accounts for 30 to 50% of the total monthly electrical charges. For this reason, compressed air as a utility should be managed and conserved.
Fortunately, compressed air management can begin with actions that produce immediate results. The biggest “bang” for the buck” principal certainly applies. First, tackle the action items that will get the ball rolling, produce significant results, and are the least difficult to implement. Here is a 10-step program in the order of this philosophy.

• 1. Educate personnel. Any successful program begins with defining the problem and explaining the tasks. In this instance, everyone in the plant using compressed air needs to understand how the cost of air is determined. (See Figure 1 - the cost of air calculation.) Also, explain how air is produced, treated, maintained, conserved and handled safely. One suggestion is to make compressed air users aware of the operating cost of individnal pieces of equipment. By helping the equipment users to realize the cost, they may be more willing to apply recommended conservation methods. Better yet, they might suggest new methods not previously considered.
• 2. Eliminate air leaks. Leaks in compressed air systems result in significantt operating expense. A 1/8-inch diameter hole in a 100-psig air line of a compressed air system costs nearly $2,000 annualy for a 24 hour-per-day operation. Begin by issuing colored tags to all personnel using compressed air. When leaks are discovered, request that they be tagged and dated for prompt maintenance. Should leaks prove difficult to find, by strolling through the plant just after quitting time and listen carefully for the hissing sound of air leaks. Preciously unnoticed leaks may be more obvious with the absence of daily production noises. For facilities working around-the-clock, ultrasound detection may help locate the elusive leaks. A break in a water pipe would certainly be repaired immediately - air system leaks should receive the same treatment.
• 3. Prevent waste. Consider installing automatic traps to prevent loss of air through pet cocks and valves left open to bleed off condensate. If electric, timed traps are installed, readjust them periodically to compensate for seasonal changes of moisture content in the air. Use pressure regulators at the point of use to avoid over-pressurization and waste. Be certain to use good quality “quick disconnects” that prevent air loss when they are coupled and uncoupled.
• 4. Air system check-up. Check your plant air system’s health. Obtain optimal operating data for your compressed air equipment. Some compressor manufacturers provide “start-up forms” that list important parameters such as amperage draw, operating temperatures, pressures, and cooling media data. Check equipment at regular intervals and compare your readings with the available base-line data. Any abnormal operating parameter is an indication of the need for corrective action.
• 5. Evaluate power costs. Review electric utility fee schedules and past bills to establish a base-line. Compressed air systems improvements can be evaluated monthly by comparing electricity costs against the established base line. Progress in cost reduction then should be reported to management. Some electric companies offer rebates for efficiency improvements. This may be useful in making decisions on system changes and equipment enhancements. Many equipment manufacturers offer options and sometimes retrofit kits for existing equipment such as Wye-Delta starting, high efficiency motors and power factor correction, which can significantly reduce electricity bills. Energy rebates and reduced electrical costs usually translate into very short payback periods of the initial investment.