Compressed air, measured and explained.
Practical writing on where compressed air energy goes, how to find the waste, and what the fixes are actually worth.
Technical field notes
Why CFM per kW Makes More Sense Than kW per 100 CFM
The compressed air industry measures efficiency using kW per 100 CFM, a metric most plant managers find unintuitive. CFM per kW flips the fraction and makes bigger-is-better, just like miles per gallon.
Read it 02Energy Cost OptimizationYour Compressor Doesn't Know What Time It Is, But Your Electric Bill Does
The same compressed air can cost more to produce at 2 PM than at 2 AM. Understanding your time-of-use rate structure is one of the fastest ways to reduce your compressed air energy bill.
Read it 03Maintenance and OperationsLeak Repair Done Right Is Expensive, And That's the Point
A push-to-connect fitting blows out. Maintenance replaces it with another push-to-connect. Six months later, it fails again. Here's why spending more on the repair saves money.
Read it 04Measurement and MonitoringYour Flow Meter Is Probably Lying to You
Flow meters are the most important instrument in a compressed air system and the most commonly installed incorrectly. Here are the four things that have to be right for accurate readings.
Read it 05Food Safety and ComplianceWhat SQF Edition 9 Actually Requires for Compressed Air, and Why BCAS BPG102 Is the Standard That Fills the Gaps
SQF tells you to monitor compressed air quality. BCAS BPG102 tells you what the numbers should be. Here's how the two standards work together.
Read it 06System Design and EfficiencyYour Compressor Room Is Cooking Itself, And It Might Be Cooking Your HVAC Bill Too
A 100 HP compressor can reject roughly 270,000 to 285,000 BTU/hr of heat into your compressor room at full load. Bad ventilation costs you capacity and efficiency. And if conditioned air is leaking into the room, your HVAC bill is paying for it.
Read it 07Energy AssessmentsWhat Is a Compressed Air Energy Audit and Why Does Your Facility Need One?
Compressed air is one of the larger electrical loads in many plants, and part of what it produces is wasted. Here is what an energy audit measures and what you get from one.
Read it 08Energy AssessmentsTop 5 Signs Your Compressed Air System Is Wasting Energy
Compressors that never ramp down, pressure creeping up, audible hissing. Five signs your compressed air system is quietly wasting energy, and what each one costs.
Read it 09Leak DetectionUltrasonic Leak Detection for Compressed Air: How It Works and Why It Matters
Leaks are one of the largest losses in many compressed air systems. Here is how ultrasonic detection finds them, what a survey looks like, and how their cost is worked out.
Read it 10Energy AssessmentsVSD Compressors: Why Variable Speed Alone Doesn't Guarantee Efficiency
A VSD compressor only saves energy if the system around it lets it. Why variable speed often underdelivers, and how to close the efficiency gap.
Read it 11Utility IncentivesHow to Maximize Utility Rebates for Compressed Air Upgrades
Many utilities fund part of a compressed air efficiency project. Here is how the incentives work and how to capture the most.
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