Energy, Dynamics, and Predictive Maintenance
Your compressed air system could be wasting up to 30 percent of its output, and you might not see any obvious signs.
Energy waste in compressed air systems rarely shows up all at once. Over time, the system becomes less efficient and operating costs rise. Many plant managers assume their compressed air system “runs fine” because production hasn’t stopped. However, that same system could be operating at 60 percent efficiency or lower, working harder than it should and slowly wearing itself down.
Understanding where and why inefficiency occurs is the first step toward fixing it. Let’s take a closer look at how to identify inefficiencies and what actions to take next.
Addressing Hidden Energy Loss.
Leak Detection
Air leaks are one of the most significant (and preventable) sources of inefficiency in a compressed air system. According to the U.S. Department of Energy, leaks waste as much as 20 to 30 percent of the compressor’s output. Undetected leaks lead to higher energy consumption and greater load on your entire system.
Most leaks occur at joints, fittings, valves, or worn seals, and they often remain undetected because they don’t cause immediate performance issues. However, the compressor compensates by working longer and harder to meet demand.
Implementing routine leak detection by using equipment like Sonotec’s ultrasonic equipment or remote flow monitoring and establishing a regular inspection protocol reduces the chance of unnecessary waste. Quantifying leakage rates and calculating the associated energy loss can quickly justify the investment in detection and monitoring tools.
System Inefficiencies
Beyond leaks, several other system inefficiencies increase energy consumption, including:
- Inappropriate pressure settings exceeding actual demand
- Improper compressor sizing that leads to frequent load/unload cycling or idle run time
- Unregulated or poorly adjusted drains
- Malfunctioning pressure regulators that allows overpressurization downstream
- Dirty or clogged filters
- Excess moisture or condensate
- Dirty or contaminated air
- Oil carryover that contaminates downstream equipment
- Degraded lubricant that increases internal resistance and raises operating temperature
- Running multiple compressors without sequencing controls that coordinate operation based on system demand
- Using compressed air for inappropriate applications, such as open blowing or cooling electrical panels
Each issue may seem minor on its own, but even one or two combined can lead to long-term performance problems.
Managing Pressure and Flow Dynamics
A compressed air system operates as a dynamic network. When one area is compromised, the system compensates in ways that increase energy consumption and cause inconsistent performance.
Optimizing the system as a whole, rather than focusing on individual parts, gives a clearer picture of what’s working, what’s not, and what changes will make the biggest impact.
Some of the most common pressure and dynamic issues we see are:
Operating Pressure
Many facilities set system pressure higher than necessary to overcome design flaws such as pressure drops from undersized piping or long distribution runs. While this might seem like a quick fix, increasing system pressure by just a few psi creates energy penalties and leads to more leaks. For systems in the 100 psig range, for every two psi increase in discharge pressure, energy consumption will increase by approximately one percent at full output flow. Higher pressure accelerates air loss through existing leaks and increases wear on downstream components.
Flow Restrictions
Long runs of narrow piping, excessive bends, and turbulent junctions create friction loss. Restrictions reduce delivered pressure at the point of use, forcing the system to operate above optimal pressure levels. Piping modifications, such as increasing line diameter, reducing unnecessary fittings, or implementing looped distribution, maintain stable pressure and improve delivery efficiency.
Receiver Tanks
Properly sized storage provides a buffer between supply and demand, allowing compressors to cycle more efficiently and reducing rapid pressure fluctuations during high-demand periods. Strategic placement of secondary receivers closer to end-use equipment can also reduce localized pressure drops.
Establishing Predictive Maintenance
Even the best-designed compressed air systems eventually wear down. Predictive maintenance identifies performance changes before they lead to downtime or equipment failure.
Instead of reacting to problems as they happen, flag changes in vibration, temperature, pressure, or flow as soon as you notice them. For example, a slow decline in airflow paired with a stable motor current might point to a clogged filter or restriction in the piping. A rise in dew point could indicate moisture buildup or a failing dryer. Tracking trends over time gives your team a proactive window into what’s happening behind the scenes.
When you know what’s normal for your system, it’s easier to spot what’s not. Predictive maintenance minimizes unplanned downtime, reduces repair costs, and keeps your system at its peak performance.
Make Preventative Maintenance Part of Your Routine
Compressed air systems run most efficiently when maintenance is consistent and aligned with your equipment’s performance. Routine checks catch issues early and prevent costly energy waste.
If building and managing a preventative maintenance schedule feels like more than your team can take on, let Air Handling Equipment handle it for you. Our compressed air specialists will customize maintenance plans based on your system’s usage and performance history. We’ll handle the inspections, service intervals, and part replacements, so your team can focus on production.
We also offer remote monitoring and compressor sequencing systems to keep you covered between visits. Air treatment tools provide real-time insight into your system’s performance, alert you to pressure drops, inefficiencies, or potential failures, and help keep energy usage in check.
If something does go wrong, we’re available 24/7 for emergency repairs, with the parts and expertise to get your system back up and running fast.
Get Ahead of Energy Waste Before it Costs You
Small issues build over time and quietly reduce system efficiency. The longer they go unchecked, the more they impact your bottom line.
Consistent attention to how your system operates prevents bigger problems down the road.
Save on operating costs and extend the life of your equipment. Contact Air Handling Equipment to schedule an on-site visit or set up system monitoring.
With office locations in Sidney, Loveland, and Gahanna, Air Handling Equipment has provided compressed air system solutions to the Midwestern and Southern Ohio markets since 1977. This includes proudly serving the greater Cincinnati, Columbus, Dayton, Lima, and Findlay, Ohio areas. We also proudly serve the Northern Kentucky Market. For questions about our selection of air compressors, call one of our locations or fill out our online contact form, and someone from our team will get back to you as soon as possible.
