REDUCING
INCREASING
A North Carolina electronics manufacturing and assembly facility supplied the air network with multiple reciprocating piston air compressors and experienced fluctuation in the air network pressure which increased the run cycles for the pumps. The company suspected that the high amount of wasted components and excessive energy energy costs were related to the varying pressure in the compressed air network. The network consisted of two reciprocating air compressors, one 3.5 Hp and other 5 Hp and the air pressure fluctuated between 104 psi and 138 psi.
The Installation: Time and Effort
Each air compressor required the installation of Compressor Controller Model R1. The total installation for both took 1 hour and 24 minutes and required two sets of additional valves: 1 vent valve NO ⅛”NPT with 1/16” orifice, and a 1 drainage valve NC ¾”NPT with 1/8” orifice to be installed on each compressor.
The main Results:
The Specifics: Details & Numbers
Air Compressor 1:
Air Compressor 2:
A North Carolina small auto body shop had to shut down operations for a day because the only reciprocating air compressor that supplied air to the shop failed when the compressor pump burned out. The mechanic replacing the pump drained and saved the oil to show the business owner the likely culprit on the burnout. The oil was heavily contaminated with condensate from the expansion tank and mixed within the pump during compression, reducing the lubrication and eventually causing the downtime. The owner was faced with a total compressor replacement and installation after about one year of operation by the previous one.
The Installation: Time and Effort
The installation of the Compressor Controller was incorporated with the new replacement compressor and was installed, connected and tested, in approximately 1 hour and 20 minutes. The compressor was equipped with two additional valves: 1 vent valve NO ⅛”NPT with 1/16” orifice, and a 1 drainage valve NC ¾”NPT with 1/8” orifice.
The Results:
The Specifics: Details & Numbers
Air Compressor 1: