Types of Compressed Air Quality Levels:
Plant Air
Air tools, general plant air
Instrument Air
Laboratories, paint spraying, powder coating, climate control
Process Air
Food and pharmaceutical process air, electronics
Breathing Air
Hospital air systems, diving tank refill stations, respirators for cleaning and/or grit blasting
Ask a Question:
How can I determine what my compressed air needs really are?
Answer:
Compressed air needs are defined by the air quality, quantity, and level of pressure required by the end uses in your plant. Analyzing your needs carefully will ensure that your compressed air system is properly configured.
Air Quality
Compressed air quality ranges from plant air to breathing air.
Industrial applications typically use one of the first three air quality levels. (listed to the left)
Quality is determined by the dryness and contaminant level required by the end uses, and is accomplished with filtering and drying equipment. The higher the quality, the more the air costs to produce. Higher quality air usually requires additional equipment such as compressed air dryers or filters that remove moisture, contaminates and oils.
One of the main factors in determining air quality is whether or not lubricant-free air (oil-free air) is required. Lubricant free air can be produced with either lubricant-free compressors, or with lubricant-injected compressors that have additional separation and filtration equipment.
Before your select a lubricant-free or lubricant-injected compressor, carefully consider the specific end use for the lubricant free air, including the risk and cost associated with product contamination.
Air Quantity—Capacity
Required compressed air system capacity can be determined by summing the requirements of the tools and process operations
(taking into account load factors) at your site.
NOTE: The total air requirement is not the sum of the maximum requirements for each tool and process, but the sum of the average air consumption of each.
High short-term demands should be met by air stored in an air receiver. Systems may need more than one air receiver. Strategically locating your air receivers near sources of high demand can be effective.
It often makes sense to use multiple, smaller compressors with sequencing controls to allow for efficient operation at times when demand is less than peak.
Load Profile
Another key to properly designing and operating a compressed air system is analyzing a plant’s compressed air requirements over time, or load profile.
The variation of demand for air over time is a major consideration in system design. Plants with wide variations in air demand need a system that operates efficiently under part-load. Multiple compressors with sequencing controls may provide more economical
operation in such a case. Plants with a flatter load profile can use simpler control strategies.
Artificial Demand
Artificial demand is defined as the excess volume of air that is required by unregulated end uses (ie: leaks, open blowing) as a result of supplying higher pressure than necessary for applications. Pressure/flow controllers can help to minimize artificial demand.
Pressure
Different tools and process operations require different pressures. Pneumatic tool manufacturers rate tools for specific pressures. Each process operation pressure requirements should be specified by the engineer(s) overseeing that process.
As you can see – a wide variety of elements affect your Compressed Air needs:
-Air Quality
-Air Quantity
-Air demands and specifications involving your tools, equipment and processes
When you consider all these areas, seek the help and information you need from proper sources, then you can achieve the efficient compressed air system you need.
*SOURCE: Improving Compressed Air System Performance: A Sourcebook for Industry is a cooperative effort of the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy (EERE) Best Practices and the Compressed Air Challenge®.
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