mb air systems
mb air systems

Compressed Air: The Facts
Why an iceberg? Compressed Air: The Facts


Why an iceberg?
A compressed air system can be viewed in a similar way to an iceberg!
The iceberg helps illustrate the hidden cost of your compressed air system.
The visible area represents the initial equipment purchase and routine servicing and maintenance.
Hidden beneath is the ever increasing & uncontrollable energy costs.
We at mb air systems, continue to strive to reduce your energy usage, by utilising innovative products and solutions

According to the British Compressed Air Society; "Electrically driven compressors are a major user of energy, accounting for around 10% of electricity costs in the industrial sector".

This could be over 10,000 GWHr of electricity, in today's terms this equates to almost £1 billion per year.

mb air systems ltd, with over 40 years of expertise, specialise in compressed air systems and all associated engineering services.

We carry out detailed compressed air system surveys and provide our clients with innovative and practical solutions which maximise their plant uptime and minimise their energy and operational costs.

 

 

     
Compressed Air Energy Costs Compressed Air Leaks Compressed Air Pressure
Air generation is often the highest cost for industry On average, air leaks equate to around 30% of compressed air output any systems run at a higher pressure than is required!
For every 2psi reduction in pressure, 1% of energy costs can be saved
     
Compressed Air Energy Costs Compressed Air Obsolete Compressed Air Sizing
Approximately 90% of the energy a compressor generates is waste heat Most of the time this is not utilized Obsolete equipment & filters can purge air and create pressure drops unnecessarily The compressor in place may not be the right choice or size for the application

 

The Standard for Audits

ISO 11011 (2013) - Compressed Air Energy - Assessment
ISO 11011:2013 sets requirements for assessing and reporting on the performance of the complete compressed air system from generation, transmission and demand.
The standard sets requirements for analysing the data from the assessment, reporting and documentation of assessment findings, and an estimate of energy saving resulting from the assessment process.
It identifies the roles and responsibilities of those involved in the assessment activity.


MB Air Systems have been endorsed by BCAS (The British Compressed Air Society) for auditing in compliance with ISO 11011!

Training & Certification
DipCam (Diploma in Compressed Air Management)
All calculations / recommendations will be approved by an engineer with a certified diploma in compressed air management from the British Compressed Air Society.


Core Competencies
To ensure that we can meet the needs of industry and be confident in establishing energy saving and operational opportunities, we regularly participate in approved training schemes from equipment manufacturers, industry bodies and external training providers.


Certification
mb air systems have demonstrated compliance with, and sound management of, current basic health and safety legislation through accreditation within the Contractors Health and Safety Assessment Scheme (CHAS) and the Achilles Verify assessment and audit process. Membership of British Safety Council and the British Compressed Air Society ensure mb air systems keep up to date with all current legislation, industry guidance and best practice

To Improve we must measure...

Audit Technology

Alongside our experience and expertise, mb air systems ltd has invested heavily in recent times to ensure that we have the most comprehensive and up to date methods to measure energy, air consumption, system performance and viability.

Our approach is tailored to suit each customers site.

ENERGY
AUDITS
  We utilise a data logger to measure the power consumed by each compressor, while at the same time measuring the system pressure downstream.
This helps to analyse the load or demand profile of your system. With this information, we can assess, advise and recommend improvements to the system control strategy
PIPEWORK
AUDITS
  Your pipework system is the transmission that carries the air to your equipment.
More often than not, poor system design or the addition of extra air lines can cause pressure drops, restrictive flow and can corrode over time. This makes the system less efficient and can mean your compressor works harder. We can map out your current system, noting areas for improvment, identify savings and advise on any health and safety implications.
LEAK
DETECTION
  Leaks can be one of the biggest costs to a systems efficiency.
We utilise ultrasonic leak detector to identify the source of leaks in your system.
The resulting report shows the location, estimated size and cost of the leaks.
We can provide costs for repairing each issue and reducing wasted energy
FLOW
METERING
  As compressors age, their output can decline.
We can provide reporting based on a “non intrusive” flow meter that can accurately determine how much output you are actually getting from your system, without the need for large capital expense or down time to install.
THERMAL
IMAGING
  The heat profile of a compressors components can be a tell tale sign of a compressors condition.
If certain components wear, they can produce excess heat, not perform their function as efficient and lead to the breakdown of other component parts in the system.
We use a specialised thermal imaging camera to display and report this.
CONTROL
STRATEGY
  Control strategy can be the difference between an efficient system and a wasteful one.
Our aim is to turn compressors off where possible and match the systems output to your demand.
Utilising pressure profiles and system isolation is key to optimising system efficiency.
REMOTE
MONITOR
  We can implement remote monitoring solutions to ensure that you can access your compressors information from anywhere, through a pc, tablet or mobile phone with an internet connection.
This allows tracking and recording, as well as the production of reports when you need them.
SERVICE   We have invested in our service capabilities to allow us to ensure that your system is running as it should and as efficiently as possible. As part of our regular servicing agreements, we provide vibration monitoring and oil analysis to identify problems before they arise and allow remedial action to take place before equipment breaks down.
ESOS   By December 2015, all businesses which have more than 250 employees or a turnover exceeding €50m, must conduct a mandatory assessment and report on their energy usage.
We can provide a detailed breakdown of costs associated with your compressed air system to aid with the ESOS procedure.

 

Case Study
The Client
A large manufacturer based in the UK which produces large volumes of insulation for the construction and home improvement markets.
They have a diverse mixture of compressor types and technologies, from the last 50 years, this includes oil lubricated rotary screw and low pressure two stage piston compressors, from a variety of compressor manufacturers.
The client had identified their compressed air as a priority for review as it is one of the biggest expenses within their process.

The Brief
mb Air Systems Ltd was invited alongside others to layout an action plan which would analyse the compressed air system within the plant. Utilising the ISO11011 assessment process, MB Air Systems were asked to present our findings to the energy and engineering team, along with recommendations on energy savings, future improvments, health and safety advice and future proofing the plant as they continue to grow.

The Process
The preliminary report we provided gave clear indication of current energy consuption that the compressed air system was using, alongside a site overview that identified areas that should be explored further.

In the following weeks, we carried out a full site review which included the following;
Air quality analysis which determined that the main dryer on site was not drying the air properly, We recommended this be turned off to save on purge air. This gave the client an immediate annual saving of £30,000.00, without the need for capital outlay

- A full ISO 11011 compliant report was completed which mapped out all compressed air assets, defined their performance and energy profiles, the transmission pipework system and identified control measures which should be applied to the demand side of the system
- Thermal imaging was carried outand reports submitted on all assets to show condition and requirement for replacement of degraded components
- Recommendations were made to replace some of the ageing inefficient equipment with modern energy efficient equivalents

The Conclusion
In conclusion, we identified that the site could reduce annual energy costs on their compressed air system by £110,284.00, 23% and maintenance costs by approximately £50,000, 53% based on our recommendations
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mb air systems brochure, engineering solutions Download Brochure