Efficient Plant Nov./Dec. 2022 - 14

feature | compressed-air systems
A food-and-beverage facility realized these savings with its sustainability eff orts. Image courtesy of Motion
primary goal is to realize immediate savings
and create a roadmap for sustained results.
Th is is achieved by identifying a baseline for
how the system is currently operating, the
potential savings (bottom-line savings and
carbon reduction), and recommendations to
alleviate the burden on the facility.
Th e overarching responsibility is to maintain
annual carbon-reduction initiatives. Th e
survey should become a standard operating
procedure that requires fewer resources
each time it's conducted. Th is will allow the
facility to be proactive in the event of failure,
or on a routine basis throughout the year.
4. Identify proactive methods to monitor
and maintain ESG commitments.
Today, technology exists to continuously
monitor compressed-air systems. Various
sensors promote the totality of a system
deployed within a facility. Overall system
parameters are essential, such as amp draw,
airfl ow, and pressure for each independent
compressor system within a facility; power
draw for each compressor; and dew point for
each dryer within the system.
To help prevent catastrophic failure, a
complete system will include vibration and
temperature sensors on each compressor to
safeguard production while allowing maintenance
personnel adequate time to order
14 | EFFICIENTPLANTMAG.COM
parts or call for service. In addition, each
unit should have an amp meter to monitor
power draw and provide analytical data
regarding compressor performance. Dryers
should have a hygrometer to detect an increase
in moisture carryover as performance
erodes. Preventing bulk water carryover
will protect the downstream equipment and
decrease the potential for leaks.
Mainline fl ow and pressure analysis from
each system within a facility will help identify
when demand either spikes unexpectedly
or increases gradually over time due to an
increased leak load. Th is allows timely maintenance
scheduling to address a known issue
instead of blindly fi xing leaks. Th e results
can be tracked in real time and reported to
management and the company stakeholders.
ASSESS. MONITOR. MAINTAIN.
Optimizing a compressed-air system and
arming it with the necessary technology to
enhance its performance and provide traceability
to sustainability goals must become
the standard. Bottom-line cost savings plus
carbon reduction off er stakeholders value
for years to come. Understanding the detriments
and opportunities of a compressed-air
system will lead to exceptional results. To
properly assess monitoring and maintain the
performance of a compressed-air system,
take the following actions:
Secure a baseline system analysis.
Understand the areas of opportunity and
take action to drive results.
Install the necessary monitoring equipment
to allow facility personnel a proactive
and educated approach to maintaining the
system.
With these important tools, a
compressed-air system can become a
shining example of optimization at the
facility instead of the fourth utility that
everyone neglects. EP
Ed Duda is Senior Manager of P²MRO at
Motion, Birmingham, AL (motion.com).
He has a multidisciplinary background in
operations and maintenance excellence and
extensive experience in operational and
maintenance strategy execution, lubrication
program development and deployment, and
applying Industry 4.0 technologies within
manufacturing facilities.
Mike Kusch is Energy Services Manager
at Motion. He has performed and provided
deliverables on hundreds of compressed-air
energy surveys across North America in a
wide span of industries for 10 years.
Learn more at Motion.com/effi cientplant.
NOV/DEC 2022

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Efficient Plant Nov./Dec. 2022

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