By Ron Marshall
Remember when your compressed air system was new? The compressors and dryers were shiny, the installation was perfect, and everything was finely tuned for optimal performance. But time takes its toll. Components wear out, sensors fail, and well-meaning adjustments can knock the entire system out of harmony, quietly costing you a fortune in wasted energy.
Over the years, things change. A pressure switch is adjusted for a temporary issue, a sensor gets clogged, or a new maintenance person, let’s call them “Mr. Fixit,” tries to optimize performance with a few turns of a screwdriver. Without a deep understanding of compressor control logic, these small tweaks can have big consequences.
This scenario is more common than you’d think. Data from countless compressed air assessments show that systems often drift far from their original efficient state.
Efficiency isn’t a “set it and forget it” feature; it relies on the careful adjustment of critical settings by qualified personnel who understand how the entire system should work together. Without regular check-ups, your system’s performance can degrade, leading to higher energy bills and unreliable operation.
The solution is to periodically re-commission your system. This means having an expert take a comprehensive look to ensure nothing has been overlooked or misadjusted. A professional assessment can quickly pay for itself through energy savings.
Here are a few important items that should be on any re-commissioning checklist:
- Compressor pressure settings: Are your pressure settings too high or the bands too narrow? Often, settings are changed in response to a one-time event and never corrected. Reviewing and optimizing these settings is a crucial first step toward efficiency.
- Lead compressor selection: Not all compressors are created equal. Some are designed to be lead machines, while others are better for trimming partial loads. Ensuring the correct operational sequence is vital for maintaining peak efficiency.
- Air dryer settings: For desiccant dryers with dewpoint controls, it’s common for sensors to foul or for the controls to be bypassed entirely. Verifying and repairing dryer operation can save a significant amount of energy.
- Automatic drains: “Airless” drains are great for preventing waste, but they can wear out and fail. A single failed drain can compromise dryer performance and air quality. Regular testing is essential.
- System monitoring: If compressed air is a major part of your electricity bill, you can’t afford to fly blind. A permanent monitoring system allows you to track performance daily, spot inefficiencies early, and maintain savings over the long term.
Don’t let hidden problems drain your budget. By investing in regular, expert assessments, you can turn hidden costs into measurable savings and ensure your system runs as smoothly as the day it was installed.
