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

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How to get the most out of your Air Compressor

Get the most out of your Air Compressor by establishing a regular, well-organized maintenance program and strictly following it.

Such a program is critical to maintaining the performance of a compressed air system and will save you time and money in the long haul. You should use the standard recommended minimum maintenance procedures for air-cooled reciprocating compressors as listed in the checklist below.

One person should be given the responsibility of ensuring that all maintenance is performed properly, on schedule, and is adequately documented.

IMPORTANT:
Before performing any maintenance function:
• 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.

DAILY MAINTENANCE OR (every 8 hours)
1. Check oil level of both compressor and engine if so equipped. Add quality lubricating oil as required.
2. Drain moisture from tank by opening tank drain valve located in bottom of tank.
3 Check for any unusual noise or vibration
4. Turnoff compressor at the end of each day's operation. Turn off power supply at wall switch.

WEEKLY MAINTENANCE OR (every 100 hours)
1. Clean dust and foreign matter from cylinder head, motor, fan blade, air lines, intercooler and tank.
2. Remove and clean intake air filters.
3. Check V-belts for tightness. The V-belts must be tight enough to transmit the necessary power to the compressor

MONTHLY MAINTENANCE OR (every 500 hours)
1. Change crankcase oil if using CHAMPLUB hydrocarbon based reciprocating oil.
2. Check entire system for air leakage around fittings, connections, and gaskets, using soap solution.
3. Tighten nuts and cap-screws as required.
4. Check and clean compressor valves, replace worn or damaged assemblies & gaskets
5. Pull ring on all pressure relief valves to assure proper operation.

ANNUAL MAINTENANCE OR (every 4000 hours)
1. When CHAMPLUB synthetic lubricant is used, lubricant change intervals may be extended to every 4,000 hours or annually whichever occurs first (change more frequently in harsher conditions).
2. Maintain lubricant level between high- and low-level marks on bayonet gauge. (Discoloration or a higher lubricant level reading may indicate the presence of condensed water). If lubricant is contaminated, drain and replace.

Click Here to Download a Free Reciprocating Maintenance Service Record Checklist Sheet

For your next order of Compressor Lubricants and Filters –
call 336-229-9999…
Or click here for SERVICE KITS and Lubricants

McGuire Air Compressors
336-229-9999
Email: compressors@mcguire.biz

http://www.industrialaircompressors.biz/

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Four keys to maintaining an efficient compressed air system

Key #1: PREVENTIVE MAINTENANCE
"What is the key to maintaining an efficient compressed air system?"
The best reply would have to be -- Preventive Maintenance.

WHAT IS PREVENTIVE MAINTENANCE?
According to "Wikipedia": Preventive maintenance (PM) has the following meanings:
"The care and servicing by personnel for the purpose of maintaining equipment and facilities in satisfactory operating condition by providing for systematic inspection, detection, and correction of incipient failures either before they occur or before they develop into major defects. Maintenance, including tests, measurements, adjustments, and parts replacement, performed specifically to prevent faults from occurring."

*Source: from Federal Standard 1037C and from MIL-STD-188 and from the Department of Defense Dictionary of Military and Associated Terms

Preventive maintenance activities include partial or complete overhauls at specified periods, oil changes, lubrication and so on. In addition, workers can record equipment information and deterioration so they know to replace or repair worn parts before they cause system failure.
The ideal preventive maintenance program would prevent all equipment failure before it occurs.

BENEFITS OF PREVENTIVE MAINTENANCE:
-Improves system reliability and helps keep equipment working and/or extend the life of the equipment.
-Decreases system downtime and actively helps prevent unbudgeted maintenance expenses from cropping up.
-Decreases the cost of having to replace equipment as often.
-Records operational data that can help you troubleshoot an emerging problem (called "Data Trending")
Data trending is the recording of basic operation parameters including pressures, temperatures, and electrical data. For example, a slowly increasing temperature indicates a variety of maintenance requirements including cooler core cleaning, overloading of system and possible mechanical problems. Another example might include slowly decreasing pressure, indicating increased system flow requirements, reduced compressor performance or increased system leakage. Make sure someone is looking at this data on a regular basis. If the data is never reviewed then the benefit is lost.

THE VALUE OF PREVENTIVE MAINTENANCE:
To determine how valuable regular air compressor PM is to you and your business... you need to know what your "down-time" is worth. In some operations, down-time can cost hundreds, even thousands of dollars an hour.

There are many misconceptions about preventive maintenance...one being that it costs too much.
This line of thinking says regularly scheduled downtime for maintenance costs more than operating the equipment until repair is absolutely necessary...or until the equipment breaks. This may be true for some components, but don't forget to consider the long-term benefits and savings associated with preventive maintenance that have been previously mentioned.
If regular Preventive Maintenance can help reduce unexpected downtime that results in loss of production, time and materials or the ruining of an expensive plant process--then it is well worth the investment. Not to mention that unscheduled shut-downs can be extended if the correct equipment parts or repair technicians are not readily available.

"How effective is your PM program?"
The answer is: "If your PM program isn't finding problems, it isn't effective."

Key #2: CORRECTIVE MAINTENANCE
Corrective maintenance, usually called "repair", is conducted to get equipment working again or fix any problems found during Preventive Maintenance.
The primary goal of maintenance is to avoid or reduce the consequences of failure of your compressed air equipment. PM is designed to preserve and restore equipment reliability by replacing worn components before they actually fail.

Key #3: ASSESSING YOUR EQUIPMENT:
When to maintain and when to replace.
Here are several factors to consider when assessing your compressed air equipment:
-How critical is your compressed air equipment? If equipment fails, what is the impact on production or safety.
-What is the age & history of your equipment.
Equipment histories will prove that most failures occur during infancy (newly installed or recently overhauled) and old-age (self-explanatory).
How many times has this equipment failed in the past?
-How much do you trust this equipment to perform as designed when scheduled to run?
-Do you need newer technology on your equipment?
Assessing the answers to these questions will help you determine when your older equipment needs fixing or replacing. Preventive Maintenance will help your equipment last longer, run better, and save you loads of money in the long haul.

Key #4: KNOWING YOUR EQUIPMENT WHAT IT NEEDS:
-Every piece of compressed air equipment should come with a set of MAINTENANCE INSTRUCTIONS and some type of operations& parts manual. Your operators should review the equipment information and keep it handy for future reference. If you purchased used equipment and don’t have the manuals, contact your equipment distributor for a copy.
- Follow the maintenance guidelines for your equipment.

Click here to view and download a Preventive Maintenance Checklist

Top 7 Air Compressor Related Formulas

Anyone who works with or helps maintain an industrial air compressor should have these valuable compressor related formulas. Print them out and keep them handy…you might need one of them next week!

1. Formula To Find: Belt Length
Compressor Flywheel OD + Motor Pulley OD X 1.57 + 2 X Shaft’s Center To Center Distance In Inches

2. Formula To Find: Motor Pulley OD
Compressor Flywheel OD X Compressor Rpm’s / Motor Rpm’s

3. Formula To Find: Tank OD
Measure Circumference / 3.1416

4. Formula To Find: Volume Of Tank In Gallons
Tank OD X OD X .785 X Tank Length In Inches / 231

5. Formula To Find: PSIA Pressure
14.7 + Gauge Pressure

6. Formula To Find: Compressor CFM Using The Time Method
Tank Gallons X .536 X PSIG Increase / Total Seconds

7. Formula To Find: Motor Max AMP Draw Before Damage Begins
Motor Data Plate AMPS X Data Plate Service Factor


FORMULA SYMBOLS & DEFINITIONS:
/ = divide
X = multiply
+ = add

AMPS = Abbreviation of the plural for Ampere, a unit of electrical current

CFM or cfm = Abbreviation of Cubic feet per minute - a unit of measurement of the flow of a air/gas or liquid that indicates how much volume in cubic feet pass by a stationary point in one minute.

OD = Abbreviation for Outside diameter is a dimension commonly used to specify the size of tubing or pipe.

PSIA or psia = Abbreviation for Pounds per square inch absolute (including atmospheric pressure)

PSIG or psig = Abbreviation for Pounds per Square Inch Gauge

RPM or rpm = Abbreviation for Revolutions per minute is a unit of frequency of rotation: the number of full rotations completed in one minute around a fixed axis. It is used as a measure of rotational speed of a mechanical component.

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/

Top 12 Compressed Air Safety Guidelines

Top 12 Compressed Air Safety Guidelines

1. Never apply compressed air to the skin or direct it at a person. Even air at a pressure of 15 psig can cause serious injury. Never use a compressed air hose to clean dirt or dust from your clothing or body.

2. When using compressed air for cleaning purposes, ensure pressure does not exceed 30 psig (per OSHA regulations). Always use goggles or a face shield over approved safety glasses for this application.

3. Wear ear protection. Exposure to excessive noise can damage hearing. Noise reducing mufflers can be fitted to machines to lessen the noise health hazard.

4. Never crimp, couple, or uncouple pressurized hose. Shut off valves and bleed down pressure before making any hose connections.

5. Use heavy duty clamps and fittings made especially for compressed air hose.
Use only the correct type and size of hose end fittings and connections.

6. Never use frayed, damaged or deteriorated hoses. Always store hoses properly and away from heat sources or direct sunlight. A hose failure can cause serious injury. Hose Reels can decrease your chances of injury, as well as help hoses last longer.

7. When blowing compressed air through a hose or air line, ensure that the open end is held securely. A free end can whip and can cause injury. Open the supply air valve carefully and ensure that any ejected particles will be restrained. A blocked hose can become a dangerous “compressed air gun.”

8. Make sure all hoses exceeding 1/2 inch ID have a safety device at the source of supply or branch line to reduce the pressure in case of hose failure (per OSHA regulations).

9. Do not use air directly from a compressor for breathing purposes unless the system has been specifically designed for such purpose and suitable breathing air filters and regulators are in place.

10. Isolating valves should be of the self venting type and designed to be locking in the "off" position so that air pressure cannot be applied accidentally while the machine is being worked on.

11. Never alter or install an A.S.M.E. safety relief valve that has a higher PSIG rating than the pressure vessel rating to which it is installed.

12. Only pressure vessels built to a national or international standard should be used for air receivers.

Provided for your safety by
McGuire Air Compressors, Inc.
336-229-9999
compressors@mcguire.biz
industrialaircompressors.biz

TOP TEN Compressed Air "Rules of Thumb"

Here are our TOP TEN Compressed Air "Rules of Thumb" that we've come up with throughout our 44+ years of experience. These are the things that our compressor customers seem to ask about most.

1. Air Compressor CFM delivery per Horse Power at 100 PSIG:
• For "home owner" type of air compressors---2 to 2.5 CFM per HP
• For Industrial Air-cooled 2-stage air compressors----3.5 CFM per HP
• For Small Vane & Screw air compressors (25 HP or less) 4 CFM per HP
• For large Piston, Screw & Centrifugal air compressors--4.5 to 5 CFM per HP

NOTE: THE MORE CFM PER HP - THE LESS ENERGY USED.

2. Air Receiver Size needed for these types of inlet control:
• Modulating Control------------ 0 to 1 gallon per CFM
• On-Line/Off-Line-------------- 3 to 4 gallons per CFM
• Stop-Start / Variable Speed--- 4 to 6 gallons per CFM

NOTE: THE MORE AIR STORAGE - THE LESS ENERGY USED


3. Amperage per Horse Power:
115 Volts-------1 phase--------10 amps per horse power
230 Volts-------1 phase-------- 5 amps per horse power
208 Volts-------3 phase-------- 3 amps per horse power
230 Volts-------3 phase-------- 2.5 amps per horse power
460 Volts-------3 phase-------- 1.25 amps per horse power
574 Volts-------3 phase-------- 1 amp per horse power

NOTE: THE MORE ENERGY EFFICIENT THE MOTOR - THE LESS ENERGY
IS USED.

4. Air Piping Size by CFM and Pressure Drop:
• Compressor Room Header--0.25 PSIG pressure drop per 100 feet of piping
• Main Line---------------0.5 PSIG pressure drop per 100 feet of piping
• Loop Line---------------1 PSIG pressure drop per 100 feet of piping
• Branch Line-------------2 PSIG pressure drop per 100 feet of piping

NOTE: THE LESS AIR PRESSURE DROP - THE LESS ENERGY USED.

5. Size Compressed Air Line Filters to be twice (2x) your compressor CFM flow rate.
• This will lower your pressure drop approximately 2-3 PSIG and save 1% on energy costs.
• Elements will last twice (2x) as long and save on maintenance costs.

6. Lowering Compressor Pressure settings 2 PSIG will result in a 1% energy savings.

7. Lowering Compressor Inlet Air Temperature 10° F will result in a 2% energy savings.

8. The average energy cost to operate an air compressor is approximately $0.10 per horse power per hour.

9. Compressed air system leaks totaling the size of a ¼" orifice, at 100 PSIG, running 24 hours a day will waste approximately $15,000 worth of electrical energy a year.

10. Using Synthetic Compressor Lubricants can save you up to 9% of the energy cost of operating your compressor.


>>>>Click here to learn more about basic air compressor maintenance>>>>

McGuire Air Compressors
336-229-9999
email: compressors@mcguire.biz

https://industrialaircompressors.biz/

https://airdryers.biz/

https://hosereels.biz/