It was a time of pioneering compressed air system auditing and implementing large storage tanks and flow controllers to go along with the drastically inefficient part loading controls of lubricated screw compressors. The late 2000s and early 2010s marked the wave of Variable Frequency Drive (VFD) controlled compressors. This offered the best part load efficiency for lubricated screw compressors across the board.

People might say “My system was inefficient, that is why I purchased a VFD compressor”, but in reality, many were misapplied, especially in multiple compressor systems which had multiple shifts with variations in load. One, two and sometimes even three compressor systems can be controlled efficiently by cascading the pressure settings, but the fact remains that pressure will be lower when demand is high, and higher when demand is low, which, in turn, increases the consumption of compressed air for unregulated demands like open blow-offs and leaks.

Most companies assume their compressed air systems are efficient if they purchase efficient equipment. However, when misapplied, inefficiencies can increase if not properly controlled. So how does one know if one’s system is efficient? Two ways:

1. Compressed Air Audit: Pay to have a QUALIFIED air auditor data log your system for a period of time, no less than a week. This will give data which will represent a complete cycle of usage from high demand during the weekday through lower demands on the weekends and evenings. This is a snapshot of time, a benchmark prior to any changes. Recommendations can be generated with forecasts of future energy costs and system performance. This is a good solution for a single point improvement. A post audit can be done to confirm recommendations are proven.

2. Airleader Compressed Air Management System with continuous data logging: This requires an investment, but has many more benefits than a one time audit. Although an audit is typically required to justify the investment, in most cases the energy savings is more that the monthly payment to implement, or if purchased outright, carries an ROI of less than two years. Airleader is recommended for compressed air systems of three or more compressors and provides compressor control, CONTINUOUS auditing and remote monitoring of a system.

Airleader is a superior controls product which can utilize any brand of rotary screw compressor; reciprocating compressors both oil free and lubricated, with part load controls including load/unload; and variable displacement and variable frequency drives. It ensures that the most efficient combination of compressors are online for the required demand, and when not required, shuts them off. Airleader can control up to 16 compressors in one system, and up to 8 part load compressors. There are analog and digital inputs which allow remote monitoring of any sensor with a 4-20mA signal, including dewpoint, vibration, temperature, flow and many more. The system demand, pressure, as well as any sensor, can be monitored through a company intranet or online. Alarm points can be set and notifications sent through email or SMS when values falling outside of acceptable parameters are recorded, notifying up to 12 people.

Airleader continuously monitors the system efficiency and reporting for daily, weekly or monthly usage are at a click of a button and can be used to track efficiency projects or approvals for custom incentives with most utility rebate programs.

For a live demo of Airleader, please contact your IAC Area Manager.