Evaluation of Compressed Air System

Compressed Air System Improvement Program

Compressed air needs vary widely depending on the air quality, quantity, and pressure levels required by the specific processes in your facility. To ensure that your compressed air system is configured properly and operates at optimal efficiency, it’s essential to carefully analyze your facility’s needs. The higher the air quality, the more costly it is to produce. At CoolAir Compressors, our Compressed Air System Improvement Program is designed to optimize your system for efficiency, performance, and cost savings.

Why Optimize Your Compressed Air System?

An improperly configured or inefficient compressed air system can lead to unnecessary energy consumption, higher operational costs, and even production downtime. By improving the performance of your system, you can significantly reduce energy costs, extend the lifespan of your equipment, and minimize maintenance needs.

Our Compressed Air System Improvement Program takes a comprehensive approach, analyzing every aspect of your compressed air system to identify opportunities for improvement.

Steps in Our Compressed Air System Improvement Program:

1. Data Gathering & System Mapping

Equipment Nameplate Data: We gather detailed specifications of all equipment involved in your compressed air system, including compressors, dryers, and filters.
Receiver Volumes: We assess air storage volumes to understand how well your system can handle demand fluctuations.
Piping Sizes & Layout: We analyze your facility’s piping sizes, lengths, and configuration to ensure the air is being delivered efficiently.
System Drawing: A comprehensive diagram of your compressed air system is created for easy reference during analysis and improvement planning.

2. Establishing a Baseline

Current System Performance: We measure the performance of your compressed air system, including pressure, airflow, and energy consumption. This allows us to establish a baseline for current performance levels.

3. Defining Required Performance Levels

We work with you to establish the required system performance levels in terms of:
- System Pressure: Ensuring the right pressure levels are maintained for optimal performance.
- Power Consumption: Measuring and targeting energy efficiency to reduce costs.
- Air Quality: Identifying the quality of air needed for specific applications to prevent contamination or downtime.

4. Performance Analysis & Cost Review

Performance Data Review: We analyze historical performance data, system operating history, and current performance levels.
Operating Costs: We calculate operating costs, including energy consumption, maintenance, and repairs, to pinpoint areas of inefficiency and over-expenditure.
Identifying Improvement Areas: Using this data, we identify key areas where your compressed air system can be improved, such as equipment upgrades, system adjustments, or maintenance practices.

5. Evaluating Alternative Configurations & Improvement Measures

We assess alternative system configurations and improvement measures, including:
- Piping Design: Optimizing air delivery through improved piping layouts.
- System Expansion: Considering the addition of more efficient equipment or storage solutions.
- Energy-Saving Technologies: Exploring technologies that reduce energy consumption, such as variable speed drives or energy-efficient compressors.

6. Optimizing Sub-Components for Efficiency

Based on our analysis, we determine the best technical and economic options to optimize the system’s sub-components. This could involve upgrading compressors, improving air filtration, or modifying pressure control settings to reduce energy usage.

7. Developing an Improvement Plan

We devise a clear plan for implementing improvements and ongoing optimization. This plan may include phased upgrades, cost-effective strategies for implementation, and timelines to ensure your system reaches its highest efficiency.

8. Maintenance & Purchasing Practices Review

We also assess your maintenance practices to ensure that your equipment is properly maintained, helping to extend the lifespan of your assets and reduce unexpected breakdowns.
We review purchasing practices to ensure you’re investing in the most cost-effective, energy-efficient equipment available, factoring in future facility needs.

9. Factoring in Current Deficiencies & Future Needs

Our program considers not just your current system’s deficiencies, but also future facility requirements. We ensure that any improvements made will accommodate potential future demands and scalability.

The Benefits of Our Compressed Air System Improvement Program:

Cost Savings: Reduced energy consumption and improved system efficiency lead to significant cost savings.
Optimized Performance: Improved air quality, pressure control, and system reliability for smoother operations.
Extended Equipment Lifespan: Regular maintenance and optimization reduce wear and tear, extending the life of your equipment.
Energy Efficiency: Minimized energy wastage, leading to lower utility bills and a greener footprint.
Proactive Maintenance: Identifying issues before they become costly problems.

Get Started with Your Compressed Air System Improvement Today!

Don’t wait for inefficiencies to drain your resources. Optimize your compressed air system with CoolAir Compressors’ Compressed Air System Improvement Program. Contact us today to learn more about how we can help you achieve lower costs, improved system performance, and long-term energy savings.

Request a consultation to start optimizing your compressed air system for maximum efficiency.

Piping Material Features Comparison
Piping Features	Stainless Steel(Type 304L)	Mild Steel	Blue anodized Aluminum Alloy
Weight (Dia 6inch, Length 6m)	127.2	169.6	29.142
Corrosion Resistant	Yes	No	Yes(100%)
Pressure drop (Dia 2 inch Length= 20m,Airflow=3 cubic metres/Minute, Pressure=10 bar)	0.25	0.4 Bar	0.1
Energy Efficiency	High	Low-moderate	High( Potential Cost savings of 34%)
Mechanical Strength	Very Strong	Very Strong	Strong
High-Temperature Rating	Yes	Yes	Yes
Installation Ease	Less Difficult	Difficult	Easy(High Flexibility and Modularity)
Installation Time	Approx 6 feet length per hour	Approx 6 feet length per hour	Approx 45 feet Length per hour
Work Hours/Manpower Required for a 2″ pipe and a 3000 feet piping	Approx 600 man-hours/8 men for 2 weeks	Approx 600 man-hours/8 men for 2 weeks	Approx 100 man-hours /8 men for less than 2 days
Annual Cost(Installation, Commissioning, and operation)	Approx 3000 dollars	Approx 7820 dollars	Approx 1300 dollars
Installation Cost Material%/Labor%	30% / 70%	25% / 75%	80% / 20%
Surface roughness	0.03	0.05	0.001
Special Tools Required (welder, threader, groove cutter)	Yes	Yes	No
Air Quality	High(Should the application require it, these pipe systems can help meet the requirements of ISO 8573-1: 2010 air quality standards.	Low( Not according to !SO 8573-2010 air quality standards)	High(Should the application require it, these pipe systems can help meet the requirements of ISO 8573-1: 2010 air quality standards.
Cost per meter	Almost 2 less than Aluminum	3 Times less than Aluminum	163.64 Dollars(Parker Transair)
Life Span( Will vary according to environmental factors, Pipe design, and Pipe grade.	30 years	40 years	20 years
Initial Cost of installations	Material : 30% Labor:70%	Material : 25% Labor:75%	Material : 80% Labor:20%
Maintenance	Difficult(Accumulation of rust under pipes and fittings which travels to machinery, may require preventive maintenance every week)	Difficult (Accumulation of rust under pipes and fittings which travels to machinery may require preventive maintenance every 3-4 days)	Easy (No accumulation of rust, may require preventive maintenance every 4 Weeks)