Energy Management

Energy Management for the compressed air sector

Get in control of your energy costs and lower your environmental impact with the latest technology for managing compressed air consumption. 

Today around 10% of industrial energy is used to create compressed air. The compressed air is an economical option but it is often used without considering that even the air costs. Today there are also completely new products and applications that are significantly more energy efficient than they were just 5-6 years ago, but still big savings can be made. 

With the latest system from CS Instrument you can only in 4 steps get in charge of your compressed air consumption and save money. 

Prepare in 4 steps the basics for a successful energy management in your enterprise. Based on the PDCA (Plan,Do,Check,Act)-cycle of well-known management systems like ISO 16001 and ISO 9001, CS Instruments presents concrete examples for the compressed air sector. Learn how your first steps could look like. Later on you can easily transfer these steps to further sectors in your enterprise and optimize your company energetically and increase the efficiency in order to save money.

Step 1: Compressed air and energy costs monitoring

The first step is to install precise flow meters for compressed air at all essential places in order to get reliable measured data. The instruments are directly mounted into the main pipes of the compressed air plant, (in the compressor room). 

Ideally the measurements should be carried out from Friday to Friday in order to get the consumption data of the compressed air plant for a complete production period. Compressed air leakages become transparent very quickly especially at weekends when consumptions should be nearly "Zero m³/h". Load behaviors of the compressors at the weekend, when the compressors only run for pressure generation of the leakages, and peak compressed air consumptions at the beginning of the week become visible.

Energy management

Step 2: Localization of compressed air leakages resp. compressed air losses

Now in the second step compressed air leakages resp. compressed air losses are localized. Determined the largest compressed air consumers. They should be itemized into single consumers like e. g. halls, floors, production lines or even single machines. As soon as the compressed air consumption is determined for each consumer it becomes very quickly transparent where which compressed air costs are generated. Even smallest leakages or compressed air losses also in case of a running production can be found quickly with CS Instrument's leak detector LD 400.

Energy management

Step 3: Transferring solutions

When you have recognized and analyzed the energy saving potential of the main line of the compressed air plant by means of chart recorders you can transfer the results of compressed air analysis to the whole piping system. This experience will help to save energy when planning and expanding the compressed air system. So it should be carefully analyzed whether it could be economically advantageous to substitute too small dimensioned compressed air lines by a new piping system with larger inner diameters. Antiquated measurement technology (e. g. measuring orifices with differential pressure, Vortex and so on) which cause a restriction of the inner diameter of the compressed air pipes should be replaced by modern flow meters without any reduction of the pipe diameter.

Ball valves which do not correctly close should be exchanged. Couplings which do no longer close should also be replaced by new ones, these are only some examples. Make use of the knowledge from steps 1 to 3 and work out continuously and carefully further solution for your whole compressed air system. An optimized compressed air system saves money – an important point in case of increasing energy costs. The use of intelligent chart recorders like e. g. DS 500 will support you with regards to this task.

Energy management

Step 4: Monitoring of optimizations

Keep an eye on your compressed air system. After steps 1 to 3 of the compressed air analysis , the recording of compressed air consumption and energy costs, the localization of compressed air leaks and compressed air losses, the transfer of the solutions to the whole compressed air system, the compressed air analysis should be continued as a continuous task as the most important step 4. For this purpose a responsible person should be determined in each department who takes care of the topic energy saving in compressed air lines.

A unique compressed air analysis will not be sufficient in order to save energy. By means of intelligent chart recorders changes of the flow rates, leakages and compressed air losses can be recognized reliably.

Energy management