7 Ways to Save Money on your Compressed Air operating costs

Here are your tips...

1.  Find and fix your air leaks
A small leak - no larger than 1/16" can cost an extra $523 a year.* Add a few other small leaks here and there until you have leaks equal to a 1/4" opening...and now that "small leak" can cost you over $8,000 a year.* It is easy to see that what seems like a small leak comes with a very high price tag over time. 

Click here to see how to estimate what percent of your CFM’s are air leaks.

2. Lower Air Pressure

A 2 psig change in pressure equals 1% change in horsepower.
Dropping pressure can change the amount of CFM used and you’ll save all that energy needed to make that CFM.  Check to see what CFM your equipment actually needs to run efficiently and adjust your pressure to save energy yet still provide the CFM required

3. Use Synthetic Air Compressor Oil and you can reduce AMP draw an average of 8%.

4. Turn off your air compressor when it is not in use.

5. Eliminate any compressed air flow restriction.
Make sure your air line filters are clean.
Make sure your piping is not too small.

6. Use ZERO AIR LOSS DRAINS

This prevents wasting compressed air

7. Keep compressor inlet filter clean
If your Compressor cannot suck in air- then it cannot blow out the air you need.

Call - 336-229-9999  or Email compressors@mcguire.biz

For Industrial Champion Air Compressors, Pumps, Manuals, Dryers

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Reelcraft Hose Reels for air hose and other industrial applications

hosereels.biz

Deltech Refrigerated Air Dyers to reduce harmful moisture
in your compressed air system

airdryers.biz

How can I help my Compressor Last Longer?

Answer: 

One of the best ways to increase the working life of your air compressor is to establish a regular maintenance program. If you have a Reciprocating Air Compressor - the following information can provide the schedule you need.

Before you perform any maintenance, always do these steps...

• Switch main disconnect switch to "off" position to assure no power is entering unit.
• "Lock Out" or "Tag Out" all sources of power.
• Be sure all air pressure in unit is relieved. Failure to do this may result in injury or equipment damage.

Get More Free Info Now...
Learn all the proper weekly, monthly & annual maintenance steps to keep your compressor working longer...

 McGuire Air Compressors

1-336-229-9999
"Real People with Real Air Compressor Experience"

Providing compressor answers that save you time and money.

How do I correctly install and adjust an Air Pressure Switch?

How do I correctly install and adjust an
Air Pressure Switch?

Answer:

We get this question a lot - so we developed a step by step set of directions to help you.

Get your PDF instructions from our resources webpage.

What does a pressure switch do?

Answer: An air compressor pressure switch is a valuable part of your equipment. The pressure switch tells your compressor when to stop and when to start and can help you save money and energy. Need to order a pressure switch? Call us - 1-336-229-9999

336-229-9999
 www.industrialaircompressors.biz
McGuire Air Compressors
"Real People with Real Air Compressor Experience"
compressors@mcguire.biz

OSHA Requires a Compressed Air Safety Shut-Off Valve

Did you know that OSHA Requires a

Compressed Air Safety Shut-Off Valve?

The OSHA Safety Standard Regulation 29CFR CHXVII Paragraph 1926.302(b)(7) states:   All hoses exceeding 1/2-inch inside diameter shall have a safety device at the source of supply or branch line to reduce pressure in case of hose failure.

Prevent dangerous air hose whips and accidents.   Protect your most important assets: Your employees and their equipment.

OSHA Compliant COMPRESSED AIR SAFETY SHUT-OFF VALVES offers simple but efficient protection to pneumatic systems in the event of a broken compressed air hose or pipe.  

Click here to see how to get the Safety Valves you need to meet OSHA standards.

Call us to order the safety valve and reels you need- 336-299-9999

_______________________________________________________

Another OSHA guideline publication states:
“Hoses, cables, and other equipment shall be kept clear of passageways, ladders and stairs.” 

OSHA says reduce your slips, trips and falls.
Slips, trips and falls constitute the majority of general industry accidents, which cause 15% of all accidental deaths, and are second only to motor vehicles as a cause of fatalities. The OSHA standard for walking and working surfaces apply to all permanent places of employment, except where only domestic, mining, or agricultural work is performed.www.osha.gov

Consider adding reels to increase safety & efficiency with your electrical cords, welding cables, air hose, oil, grease, liquid/water or fuel hoses.  This could be one of your most effective equipment additions you’ll ever make…as well as one of the safest!

For more about Hose Reels visit www.hosereels.biz


McGuire Air Compressors, Inc.

"Real People with Real Air Compressor Experience"
336-229-9999
compressors@mcguire.biz

For Industrial Champion Air Compressors, Pumps, Manuals, Dryers

www.industrialaircompressors.biz

Reelcraft Hose Reels for air hose and other industrial applications

www.hosereels.biz

Deltech Refrigerated Air Dyers to reduce harmful moisture in your compressed air system

www.airdryers.biz.

Three Biggest Pay-Offs in changing from mineral oil-based lubricants to Synthetic Compressor lubricants

In today’s competitive and challenging market - you need every advantage you can get! 

One simple, yet very significant advantage is selecting Quality Synthetic Compressor Lubricants over conventional, mineral oil-based lubricants for your air compressor.




Three Biggest Pay-Offs in changing from mineral oil-based lubricants to Synthetic Compressor lubricants.

#1.  Lower Your Electric Bill by increasing energy efficiency

Compressor Synthetic Lubricants can actually reduce energy consumption in many applications, up to 9% as compared to conventional mineral oils.

   Here's how...
> Compressor Synthetic Lubricants help minimize friction between moving parts. ( less friction = less amp draw )

> Energy can be lost due to "churn" as mechanical parts move through oil: Compressor Synthetics Lubricants have a lower viscosity when compared to mineral counterparts of the same ISO viscosity grade , resulting in lower churn energy loss than a mineral oil.



#2. Get a Better Return on Your Investment by extending equipment life

When you lower the energy consumption with compressor synthetic lubricants you decrease friction which means less wear. Less wear = longer life.

Whether your equipment runs in extreme hot or in cold conditions, Compressor Synthetic Lubricants are more effective over a wider range of operating temperatures than mineral-based products.

>In very hot conditions, Compressor Synthetics remain thicker for better protection.  Compressor Synthetics do not degrade in high temperatures as fast as mineral-based oils either. 

>In lower temperatures, Compressor Synthetics offer excellent flow characteristics, unlike mineral-based oils that tend to get too thick to flow well when cold and can limit protection to critical parts.



#3. Lower Maintenance Costs by using Less Labor & Materials

Compressor Synthetic Lubricants usually last up to 8-10 times longer than mineral oil equivalents. This translates into...
>Reduced oil purchases
>Less used-oil to dispose
>Fewer oil changes - fewer hours your maintenance team must spend on oil changes

>Decreased downtime because of lubricant-related problems such as valve maintenance.

Click here to learn more valuable tips>>


McGuire Air Compressors, Inc.

“Real People with Real Air Compressor Experience”

Email us: compressors@mcguire.biz
Call us: 336-229-9999

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We need more air pressure! How do I figure out how much more we need?

­­­Does your air pressure keep dropping while you are using your tools & equipment?

Have you added or are planning to add new equipment which uses air?

Are your air compressors working hard all the time- but you just aren’t sure how to figure how much more horsepower you need?

When your business counts on air – you need to know the valuable formulas and steps to help accurately determine how many CFM you use. You also need to know how to accurately figure how much additional CFM and horsepower you need when considering a new air compressor?

Here are some specific formulas that can help you determine how many CFM you presently use and how many more CFM you need to meet your desired PSIG. We will show you how to take this information and use it to determine how much air compressor horsepower you actually need.

Find out how many CFM your air compressor delivers

1. STOP the compressor unit

2. CLOSE the outlet valve on the tank/air receiver

3. DRAIN the condensate from air receiver until there is 0 PSIG -
then close the drain valve

4. NOTE THE TIME- in minutes & seconds (Best to write it down.) Then START THE UNIT.
When the compressor unit stops and unloads – then NOTE THE TIME again – in minutes & seconds. Convert the minutes into seconds and then total the number of seconds it takes between START and STOP/UNLOAD.

5. NOTE the GUAGE PSIG reading

6. NOTE the Air Receiver/Tank GALLON SIZE

7. USE THIS FORMULA:

TANK GALLONS x .538* x PSIG divided by SECONDS

EXAMPLE:

You have an 80 gallon tank, your total start to stop/unload time was
3 minutes and 30 seconds. Change the minutes to seconds timed
(60 x 3= 180 seconds plus 30 seconds which totals 210). You will use the total number of seconds (210) and the noted 175 PSIG within the formula as shown below:

80 multiplied by .536 = 42.88
42.88 multiplied by 175 (Example PSIG) = 7504.00
7504.00 divided by 210 (total seconds)= 35.74 CFM delivered

The example shows that the air compressor is delivering 35.74 cfm

Your Response to this evaluation should be to compare this number with what your air compressor manufacturer says your CFM should be and evaluate how efficiently your compressor is running.
If your air compressor is within 10% of manufacturer's specifications, then the unit is OK, if not - repair unit and recalculate your needs.

 

Find out how many more CFM you need to raise your PSIG

1 What is your desired pressure ______?
(Our Example125 psig)

2. What is your present operating pressure_______?
(Our Example 70 psig)

3. Divide desired pressure by present operating pressure
(125 psig divided by 70 psig = 1.79)

4. This gives us the X-factor needed for this formula (1.79 )

5. Multiply present air compressor cfm (35.74) by your X-factor (1.79)
(35.74 X 1.79= 63.98 This gives you the total cfm needed –
which is 63.98 for our example)

6. Deduct your present cfm from the needed cfm
(63.98 minus 35.74 present cfm = 28.24)

7. This gives you the additional cfm needed to raise your psig to the level you actually need. (which is 28.24 additional cfm for our example)

 

Translate your answers into how much horsepower you actually need to operate

Divide your additional cfm needed by 3.5* (see the chart for your *actual compressor type & horsepower)
(28.24 ÷ 3.5 = 8.07 hp, which would be the additional horsepower needed for our example)

This will give you the additional horsepower you actually need.

(We will need to round up the 8.07 hp to 10 hp needed for our example. You will have to round up to the nearest standard
horsepower also.)

*CFM per compressor horsepower chart:

3.5.cfm per hp for small piston compressors ½-30 hp

4 cfm per hp for large piston 40 hp up & small screw compressors 2 hp-30 hp

4.5 cfm per hp for 40 hp-150 hp medium hp screws

5 cfm per hp for 200 hp-2000 hp large screw & centrifugal compressors

Note: Always buy CFM of delivered air at the PSIG you need…not horsepower.

Note: Always invest in at least 20% more CFM than your equipment needs. This will cover extra air usage for such things as air leaks and wear.

Follow these formulas and you can figure just how much more CFM and air compressor horsepower you really need to get the job done!

 

Compressor Terms you should know:

Cubic Feet Per Minute (cfm) - Volumetric air flow rate.

"psig" means pounds per square inch, GAGE pressure. Gage pressure is the absolute pressure of something, with the atmospheric pressure subtracted. In practice, when someone gives a pressure in just "psi" they probably mean gage pressure. If they mean absolute, they should be using "psia."

Gauge Pressure - The pressure determined by most instruments and gauges, usually expressed in psig. Barometric pressure must be considered to obtain true or absolute pressure.

Load Time - Time period from when a compressor loads until it unloads.

Unload - (No load) Compressor operation in which no air is delivered due to the intake being closed or modified not to allow inlet air to be trapped.

Receiver - A vessel or tank used for storage of gas under pressure. In a large compressed air system there may be primary and secondary receivers.

McGuire Air Compressors
“Real People with Real Air Compressor Experience”
336-229-9999
Email: compressors@mcguire.biz
or Champion Air Compressors...
https://industrialaircompressors.biz/

For Reelcraft Hose Reels
for Air, Water, Oil & fluid plus Electric Cord Reels & Welding Cable Reels...
https://hosereels.biz/

For Deltech Refrigerated Air Dryers
to remove moisture from your compressed air system...
https://airdryers.biz/

How to find out how many CFM your compressor delivers

Here's one of the most used Compressed Air formulas
you should keep on hand...
How to find how many CFM
your air compressor delivers.

Follow these steps to find how many
CFM Your Air Compressor delivers

1. STOP the compressor unit

2. CLOSE the outlet valve on the tank/air receiver

3. DRAIN the condensate from air receiver until there is 0 PSIG -then close the drain valve

4. NOTE THE TIME- minute & second. Then START THE UNIT.
When unit stops/unloads – then NOTE THE TIME again – minute & seconds. Convert minutes into seconds and then total number of seconds it takes between START and STOP/UNLOAD.

 5. NOTE the GUAGE PSIG reading

6. NOTE the Air Receiver/Tank GALLON SIZE

7. USE THIS FORMULA:

TANK GALLONS x .538* x PSIG divided by SECONDS
 
EXAMPLE:
You have an 80 gallon tank, your total seconds timed were 189 and you noted 175 PSIG.

80 multiplied by .536 = 42.88
42.88 multiplied by 175 (example PSIG) = 7504.00
7504.00 divided by 189 (total seconds)= 39.71 CFM delivered

You now know that your air compressor is delivering 39.71 CFM

Your Response to this evaluation should be to compare this number with what your air compressor manufacturer says your CFM should be and evaluate how efficiently your compressor is running.

   

 McGuire Air Compressors, Inc.
"Real People with Real Compressor Experience"

336-229-9999

www.industrialaircompressors.biz

www.hosereels.biz
www.airdryers.biz

8 Reaons to upgrade to Synthetic Air Compressor Oil

Whether you are the business owner or the one who does equipment maintenance…you’ll save time and money by upgrading from mineral-based oils to quality Synthetic Air Compressor Lubricants.

If you are the business owner – you’ll love saving money because you upgraded to synthetic oil!

If you are the one who changes the oil - you’ll be glad to make a lot less oil changes!

Eight proven benefits from upgrading to quality Synthetic Air Compressor Lubricants in Reciprocating Type Compressors:
1- Saves 7%-10% in Electrical Usage in Reciprocating Type Compressors
2- Creates Less Friction which Equals Less Wear
3- Oil Will Last up to 8 Times Longer than mineral based oils
4- No Carbon deposit build-up in Valves or Rings
5- Creates Thermal Stability & Solvency
6- No Seasonal Oil Change as with mineral oil
7- Less Impact on the Environment
8- Saves on Labor & Disposal Cost

Eight proven benefits from upgrading to quality Synthetic Air Compressor Lubricants in Rotary Vane Type Compressors:
1- Saves 8%-12% in Electrical Usage in Rotary Vane Type Compressors
2- Creates Less Friction which Equals Less Wear
3- Synthetic Oil Lasts up to 4 Times Longer than mineral based oils
4- No Carbon build-up in Vanes or Ports
5- Results in Thermal Stability & Solvency
6- No Seasonal Oil Change
7- Less Impact on the Environment
8- Save Money on Labor & Disposal Costs


Upgrading to a good quality Synthetic Compressor Oil gives you leading edge technology in lubricants:
- Profit from big savings overall, even though the initial cost a bit more
-Improve fire-resistance because of the properties of synthetic oils. Cleaner valves and less lubricant reduce the chance of fires and explosions in reciprocating air compressor systems
-Synthetic oils provide cleanliness in reciprocating air compressor crankcases that result in better heat transfer and prevention of moving parts sticking. The result can be less power usage.

There are lots of high-tech, scientific reports about synthetic lubricants you could read, but the bottom line is this: Upgrade to Synthetic Air Compressor Lubricants and save time and money!

Note: Not all synthetic compressor oils are the same. The quality and quantity of the base stocks and additives package are where the difference is. Remember the old saying – “You get what you pay for”? In this case – it’s really is true. Make sure when you upgrade from mineral oil to synthetic that you drain the mineral oil for a complete change. Don’t just “ADD” the synthetic oil to the old mineral oil.

McGuire Air Compressors
“Real People with Real Air Compressor Experience”
336-229-9999
Email: compressors@mcguire.biz
or Champion Air Compressors...
https://industrialaircompressors.biz/

For Reelcraft Hose Reels
for Air, Water, Oil & fluid plus Electric Cord Reels & Welding Cable Reels...
https://hosereels.biz/

For Deltech Refrigerated Air Dryers
to remove moisture from your compressed air system...
https://airdryers.biz/

How much does your air compressor cost you in electrical energy?

Before we see how much electricity costs, we have to understand how it’s measured. When you buy gas they charge you by the gallon. When you buy electricity they charge you by the kilowatt-hour (KWH). When you use 1000 watts for 1 hour - that unit of energy is called a kilowatt-hour. The kilowatt hour is most commonly known as a billing unit for energy delivered to consumers by electric utilities.

Once you know how much it is costing you in electrical energy…what can you do to REDUCE those costs and save money?


Seven Steps to figure the electrical energy cost of running your air compressor:
Take these first 3 steps to figure your Electrical Cost per Kilowatt Hour (KWH) (we shall use some average examples to help you see how this works)


1. Find your electrical utility bill for the facility where your air compressor operates and find your total amount due on your utility bill.


2. From your utility bill, find the total kilowatts used


3. Use this FORMULA:  Total Amount Due ÷ Total KWH Used = KWH Cost


Example:Total Dollar Amount Due Ex: $300.00
Total KWH Used Ex: 2500
Amount Due Divided By Total KWH Used
$300.00 Due ÷ 2500 KWH Used = 0.12 Per KWH
Results: Your Cost Per Kilowatt Hour is $0.12 Cents
(you will use your cost per KWH in the next formula)


In the next 4 Steps – let’s figure the ELECTRICAL ENGERY COST of running your Air Compressor
(we shall use some average examples to help you see how this works)


4. Determine your TOTAL HORSEPOWER (TOTAL HP) using this formula:
Motor Data Plate HP (EX: 25HP) X 110% = (27.5 HP)
NOTE: Most air compressors @ Max PSI use 110% of the rated horsepower


5. Figure your YEARLY HOURS of operation:
# Hours running per day X # days per week X # weeks per year running = The total time the equipment runs in a year.
(Example: 10 Hours Per Day X 5 Days Week X 52 Wks = 2600 HOURS)


6. Find your MOTOR EFFICIENCY (EFF):
MOTOR EFFICIENCY can be found on the motor data plate as a percentage.
(Example=.90 %)  It is the ratio of input power minus the output power.


7. Use this FORMULA:
Total HP x .746* x yearly hours compressor operates x KWH cost ÷ motor efficiency = Your Annual Electrical Cost to Operate Your Air Compressor

Using our EXAMPLES given…you can see how to figure your annual electrical costs:
27.5 hp x .746* x 2600 hours x $.12 ÷ .90 = $7111.87 per year to run your air compressor

EXAMPLE ANNUAL ELECTRIAL COST FOR COMPRESSED AIR = $7111.87


Most likely – your air compressor’s electrical costs were a lot more than you thought. Now that you know how much your Air Compressor is costing you in electrical energy…what can you do to REDUCE those costs and save money?
_______________________________________

McGuire Air Compressors
“Real People with Real Air Compressor Experience”
336-229-9999
Email: compressors@mcguire.biz
or Champion Air Compressors...
https://industrialaircompressors.biz/

For Reelcraft Hose Reels
for Air, Water, Oil & fluid plus Electric Cord Reels & Welding Cable Reels...
https://hosereels.biz/

For Deltech Refrigerated Air Dryers
to remove moisture from your compressed air system...
https://airdryers.biz/

*NOTE: Where does the “.746” come from?
746 watts per hour of electrical energy is required to convert to 1 Horsepower of mechanical energy. KWH= your cost per 1000 watts of electrical energy per hour. KILOWATTS per HP = .746 watts

What size piping does your compressed air system need?

Figuring the correct pipe size for your compressed air distribution system is an important task.  Pipe that is sized too small can create big pressure losses and reduce operating efficiency. Replacing piping is costly.  On average, 70% of a contracted piping job goes for labor and 30% for materials.
Do you know the biggest mistakes made in figuring compressed air piping sizes?

 Many people who plan the piping never consider the fittings or the future.

FITTINGS: Every pipe fitting creates a certain amount of increased frictional air loss that is equal to a specified length of pipe. For every 100 feet of pipe you will have a ONE POUND PRESSURE DROP caused by frictional air loss.
Any turns in the pipe at fittings, ells, tees, and valves increase pressure drops even more.  That’s why the EQUIVALENT LENGTH OF PIPE (FT.) for PIPE FITTINGS chart was developed to help you determine the best pipe size for your system.

FUTURE:
Are you planning to add more equipment in the next year or two?  Then plan for larger piping now.  Since the material costs in piping are low compared to installation or replacement cost, it’s wise to select pipe of an adequate size. If there is any doubt that a pipe size may create a pressure drop, use the next largest size. Remember that an oversize pipe compensates for possible scale build-up and provides for future expansion of the overall air system.

Steps to figuring what size piping your compressed air system needs:

1.     Determine your air compressor’s maximum CFM.

2.     Draw a piping schematic and show all pipe fittings, valves, etc.

3.     Measure and write the corresponding lengths of pipe on your schematic, then total the length of all straight pipes needed and note that on your schematic.

4.     Using TABLE 1  find your compressor’s CFM number on the far left column, and then go to the right until you see the column header with nearest length in feet to your total pipe length. Find where the CFM & PIPE LENGTH intersect on the chart and it will show the recommended pipe size for that length.

5.     Take that pipe size to TABLE 2 and use the table to find all the EQUIVELENT LENGTHS OF PIPE needed for each PIPE FITTING.  Write these lengths on your piping schematic at each fitting.
     
6.     TOTAL all the EQUIVELENT LENGTHS OF PIPE needed for each PIPE FITTING and add to your total of straight length of pipe.  This will give you a new and more accurate total pipe length needed.

7.     Take your new total of EQUIVELENT LENGTH OF PIPE IN FEET back to TABLE 1 and use this number to determine the PIPE SIZE you need.

8.     Think of the FUTURE!

Now is the time to plan for larger piping that may needed for additional future equipment.

Table 1




Table 2



For more information on Compressed Air Basics visit

http://www.industrialaircompressors.biz/free-basic-compressed-air-information

McGuire Air Compressors, Inc.
336-229-9999

McGuire Air Compressors also sells industrial products on line:

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