By Ron Marshall for the Compressed Air Challenge
A fabricator of copper tubing products had a large and expanding plant with three separate compressed air stations located in three different areas. One area was constantly complaining of chronic low pressure events, so the maintenance staff decided to install an extra compressor in a fourth location, complete with air dryer and receiver. The plant staff started the unit and let it run, content that the problem would be solved.
The compressor they chose had a basic electronic control with minimal status outputs. This compressor ran in the quiet corner of the plant for many years in a trouble free manner. Maintenance staff indicated it was the best compressor of the bunch.
An air auditor did a walk through assessment of the compressed air systems. When he started checking the extra compressor he scratched his head. The compressor was obviously running, but its output line was cool to touch. A check of the amps showed lower than rated values. The auditor came to the conclusion that, although running and consuming considerable power, the compressor was not producing any air because it was in the unloaded condition.
A check of the operating hours showed the compressor had very few loaded hours, most of the compressor life had been spent running unloaded. Operating costs in this position were estimated at $9,000 per year.
The auditor placed the compressor in “auto” mode and it immediately timed out and shut off, for the first time in many years. Plant operating staff were very interested in what this “auto” setting was all about, and were duly informed. The unit now sits armed ready to start on occasional low pressure events, but times out and turns off when not required. It turns out adding the compressor’s storage receiver to the system solved most of the low pressure complaints.
Learn more about compressor controls in our next Compressed Air Challenge seminar in your area. Visit www.compressedairchallenge.org for more information.
Filed Under: Pneumatic Tips