by the DOE find that in industrial facilities up to:
• 30% of the air produced is lost due
• 15% of the energy consumed for air
generation is wasted due to system over pressure
• 20% of energy consumed in rotary screw
or centrifugal screw based systems is lost
due to inefficient system modulation
• 20% of the energy consumed is do to
incorrect application of compressed air technology
systems use 40% less connected HP than non-optimized systems
and their Operations and Maintenance cost per CFM is 40% less.
In other words total potential savings in large, multi air
technology, uncoordinated systems is 40 to 70%.
Compressor Parts offers full system optimization including:
Leak Detection Services: We use variable frequency
ultrasonic devices and we are constantly amazed at how many
practitioners of ultrasonic inspection don't completely understand
the basic physics behind this versatile technology. Frequently
they do not know the "true" frequency response of
their instruments, or the process by which ultrasonic signals
are translated for listening, trending, and spectral analysis.
The lack of this knowledge can result in a false sense of
security, unrealistic expectations, and a failed program.
This ultrasonic air leak detector makes use of a newly developed
digital technology, where the ultrasound (20-100kHz) produced
for instance by a compressed air leak, is transformed into
a digital signal which the user can see. All leaks are field
tagged according to size and their location noted on drawings.
An economic analysis determines which should be fixed and
those that should be monitored. Typically less than 15% of
the leaks account for 85% of the air loss volume. These quick
pay back projects (less then 4 month return) are highlighted
Cost of Leaks
Air supply works best as inputs to a continuous loop Precision
Compressor Parts will analyze and if recommend design changes
require to establish proper loop design and Capacitance.
Almost all process system equipment is designed to run at
a air system pressure of 80 PSIG yet according to DOE analysis
the average plant maintains a 107 PSIG system pressure. This
excess pressure requires 13.5% more energy. Our experts will
analyze the process air users to determine high-pressure operations
and amplitude/duration of demand so that such high-pressure
applications if they exist, can be individually managed leaving
the system to operate at lower more efficient pressures.
A survey will be undertaken to ensure most effective technologies
are maximized and that best modulating technologies are used
for swing loads. Large reciprocating compressors generate
5.2 –5.7 CFM/HP and loss only 5% efficiency in the operating
capacity of 10% to 100% load. Rotary screws in the modulating
mode drop from 3.8 CFM/HP to 0 CFM/HP at 50% load so arranging
the best technology in the system for swing and base load
can save over 20% of you system energy cost.
Proper controls not only maintain safety to individual machines
they ensure the technology and size of machine is used to
maximum effectiveness. Plant wide control systems can reduce
air cost up to 30% and when connected to economic algorithms
provide operations minute-to-minute system cost visibility.
Precision Compressor Parts will analyze maintenance and purchasing
methodology and analyze common spare potential and develop
a program blend of OEM and aftermarket supply to ensure that
required costs are minimized.
have spent a lifetime servicing this technology let us help
you improve your operation.
Fax: 770-521-9995 E-mail:
3200 Engineering Parkway - Alpharetta, GA 30004
24 Hours a Day - 7 Days a Week