As important as electricity, water and gas are to any facility, most manufacturers also rely on a fourth utility. It comes in the form of a reliable supply of compressed air.
Effective pneumatic systems need properly sized, installed and maintained components from compressors to workstations. A few wrong choices, however, can lead to everything from wasted energy to system failures.
Consider the following steps when looking to maximize the performance of your company’s all-important 4th utility:
A pneumatic system’s required filtration is governed by a standard known as DIN ISO 8573-1. This identifies the solids, water and oil that need to be separated out of a well-functioning system. Required levels of filtration are defined right down to the micrometer.
And don’t simply rely on the levels you have followed for years. The standard was recently updated.
This process sounds simple: remove the compressor’s filter and clean it. But the related procedures can vary, depending on whether the system relies on a reciprocating, rotary screw or rotary centrifugal compressor. Maintenance manuals can offer some important guidance here.
Some system designers size their compressors based on the hungriest workpiece in the system, but this can introduce an array of unwanted costs. Everything from the tubing to the ports and Filter Regulator Lubricator (FRL) units will need to be larger than the other workpieces require, and the oversized compressor will waste energy.
In contrast, adding a pressure booster – which works much like a reservoir – could support main operating pressures that are much higher yet still meet the unusual demands of an individual workpiece.
The modular joiner is a plate that allows two sizes of air filtration units to be mated together. This allows system designers to size individual filtration units based on actual flow requirements and add larger individual filtration units to avoid restrictions that would otherwise occur. Fine filtration is one example.
Workers have been known to adjust a system’s overall pressure to get more air to individual workstations. In the process, they can choke or starve other stations. Opening a regulator to increase flow can also damage a sealing system, waste energy or even cause physical harm. This is why it is important to keep the regulators under lock and key.
A flow sensor that fits in line with an FRL unit, or is installed at a workpiece, can identify blocked filters that would otherwise go unnoticed. Blocked filters restrict air supply, allow contaminants to build up, and can eventually contaminate a system or kill the flow of air no matter what a compressor is generating.
Every system requires some form of ongoing maintenance. This will ensure lubricators have the oil they need and remove contaminants as varied as rust, metal shavings, water and unwanted oils.
If you know what to look for, cost savings can be identified and remedied before they turn into major system issues that can cost thousands of dollars in downtime and rebuild.
Many oils used in compressors are not suitable for the sealing system in pneumatic components. A leak from the compressor can result in premature wear or failure of sensitive valves, cylinders and other pneumatic components. Additionally, leaks are an expensive and often overlooked issue in systems. Ensure the systems are sealed of any unwanted air leaks and protect your bottom line.
At the end of the day, these are minor things that can be remedied without a third party and are costs that can add up quickly for your company or employer.
If you’re interested in learning more about managing your pneumatic system?