The requirement for compressed air is determined by the individual air consumers. This is calculated by adding up the air consumption of all tools, machines, and processes that will be connected, and then estimating their individual utilization factor by experience. It's essential to factor in potential leakage, wear, and future changes in the air requirement right from the start.
So, how do we calculate the compressed air requirement? Here's a simple approach:
The utilization factor for tools can be challenging to estimate, we recommend that the calculated values should be compared with measured consumption in similar applications. For instance, large air-powered consumers like grinders and sandblasting machines are used frequently for extended periods of continuous operation (3-10 minutes), despite their low overall utilization factor. This cannot truly be considered intermittent operation, and it's necessary to estimate how many machines will be used simultaneously to estimate total air consumption.
The compressor capacity is essentially determined by the total nominal compressed air requirement. The compressors' free output flow rate should cover this rate of air consumption. The calculated reserve capacity is primarily determined by the cost of lost production resulting from a potential compressed air failure. The number of compressors and their mutual size are determined principally by the required degree of flexibility, control system, and energy efficiency. In an installation where only one compressor supplies compressed air (due to cost restrictions), the system can be prepared for quick connection of a portable compressor as part of servicing. An older compressor used as a reserve source can serve as inexpensive reserve power.
Understanding your operations makes decision-making much easier.
An operating analysis provides key factors about the compressed air requirement and forms the basis for assessing the optimal amount of compressed air to produce. Most industrial companies are constantly evolving, which means their compressed air requirements also change. It's therefore important that the compressed air supply is based on the current prevailing conditions, with an appropriate margin for expansion built into the installation.
An operating analysis involves measuring operating data, possibly supplemented with the inspection of an existing compressed air installation over a suitable period of time. This analysis should cover at least one week of operations and the measurement period should be selected with care to represent a typical case and provide relevant data.
The stored data also provides an opportunity to simulate different measures and changes in compressor operations and to analyze the impact on the installation's overall economy.
Factors such as loading times and off-loading times also enter into the total assessment of compressor operations. These provide the basis for assessing the loading factor and the compressed air requirement, spread over a day or a work week. Accordingly, the loading factor cannot just be read off of the compressor's running hour meter.
An operating analysis also provides a basis for potential energy recovery. Often, more than 90% of the energy supplied can be recovered. Furthermore, the analysis can provide answers relating to dimensioning as well as the operating method for installation. For example, the working pressure can often be reduced at certain times and the control system can be modified to improve compressor usage with changes in production. It's also fundamentally important to check for leakage. For the production of small quantities of air during the night and weekends, it's worth considering whether installing a smaller compressor to cover this requirement is a viable option.
In summary, understanding how to calculate and measure compressed air requirements is crucial. It not only ensures efficient and cost-effective operations but also contributes to the reliability and success of your compressed air system.
Read more on the different aspects of dimensioning compressor installations in the links below.
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Installing a compressor system is easier than it used to be. There are still a few things to keep in mind though, most importantly where to place the compressor and how to organise the room around the compressor. Learn more here.
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There are a lot of things you have to consider when choosing an air compressor for your business. In this article we will explain what compressor is best suited for you, based on your application and needs.
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There are different ways we can treat compressed air and different tools that are used in these processes. Learn more about the process of regulating compressed air flow here.
