Tag Archives: system

Dental Compressor

The Costs of Compressed Air Energy

The operation of an air system requires more than just an ability to turn the right switches. One of the most important aspects of the whole operation is the maintenance of the compressor and various other components, because this ensures long life and efficiency for an air system.

One of the biggest compressed air maintenance mistakes is to underestimate or miscalculate the amount of energy that a compressor will use within the span of a year. Fact is, the price to operate a dental air compressor can equal or exceed the purchasing cost of the machine in the space of just 12 months. Most problematic in this regard is the wasteful usage of a compressed air system, which often occurs when operators are unaware of the overall energy costs.

On average, an industrial air compressor will retail in the ballpark of $30,000 to $50,000. When you multiply the operating costs per hour by the number of usage hours per day across 12 months, the cost of operating the machine during the first year alone could well exceed the initial price, and that doesn’t even count any possible maintenance costs.

A reliable way to estimate annual energy costs is to take the compressor’s horsepower and multiply that by .746, then multiply that by the number of usage hours, then multiply that by the power rate, and finally divide the total by the motor efficiency.

To best assure efficiency, it’s important to accurately calculate the annual energy costs of an air compressor, and to make sure that all operating staff understand how the figure plays out on a daily basis. That way, wasteful system use can be curbed going forward.

Even though the compressor is the main component of concern within an air system, it’s not the only one in need of routine maintenance. Of equal importance during any maintenance inspection are the other components that facilitate the air supply. Chief among such components is the air receiver, which holds compressed air for times when air demands increase, and also reduces system wear and contamination.

The air receiver makes it possible to run the compressor at lower levels and conserve energy in the process. However, the air receiver won’t be able to do its job properly if it’s too small for the system, because the compressor will have to run longer than necessary to keep up with air demand. Therefore, it’s important to ensure that the air receiver is either large enough for the system, or backed with secondary receivers.

Dental Compressor

The Problems of Dental Air Compressor

One major problem that emerges in compressed air systems is pressure drop, which is marked by a loss of pressure between the compressor and the end point. While a certain amount of pressure drop is inevitable, it should never amount to more than a 10 percent loss of pressure during a given application. Otherwise, higher pressure demands end up being placed on the compressor, which results in more rapid wear and tear across the entirety of an air system.

For each pound of pressure either increased or decreased, a power plus or minus 0.5 percent is required. For example, a five percent power savings can be gained with a decrease of 10 psig. On a 100 hp compressor, this would translate to $1,740 in annual energy savings.

Pressure drop is usually caused by trouble with the pipes and weaknesses at the filters and dryers. Unfortunately, system operators will often compensate for the pressure loss by boosting the system pressure, which results in costlier operations. The correct way to handle this issue is to check for problems at the filters and dryers and replace certain items as necessary.

It’s crucial for air system pipes to remain clean and free of dirt, rust or other contaminants. After all, compressed air reaches its end point through these pipes. When contaminants are present, air pressure weakens, and the problem gradually accelerates when left un–rectified. The pipes should always remove air from the top of the air line, otherwise contaminants will travel to the pneumatic tools.

Airstream contamination increases with velocity, which in turn increases with restrictions in pipe size. Basically, the velocity of the pipes that run to the end point should be 50 seconds or less, while the interconnecting pipes and main headers should have velocity in the range of 20 to 30 feet per second. System velocity can be calculated by dividing the flow in cfm by the pipe’s compression ratio, divided by the pipe area, divided by 60.

Another factor that can impact condensation is the ambient temperature that surrounds a facility. Simply put, condensation levels multiply as temperatures rise from average to humid. For example, a 200 hp compressor will produce roughly 50 gallons of condensate over the course of a 60–degree day. However, that same machine will generate more than five times the amount of condensate if the temperature is 30 degrees higher. A 200 hp compressor will produce roughly 50 gallons of condensate over the course of a 60-degree day.

Further inefficiency can stem from problems with the system drains, which are designed to deal with condensation. Drains are placed at strategic points along a dental air compressor system, such as the tank, dryer and aftercooler. The trouble emerges when the drain fails to do its job properly, and sludge accumulates along the drainage points from a mix of water, oil and dirt.

Some of the most common mistakes in compressed air maintenance are easily avoidable if everyone on an air system staff understands how to properly care for the equipment at hand. From the compressor itself to the various parts that make up an air system, routine inspections along key areas must be made for signs of wear, condensation and dirt deposits.

Dental Compressor

The Importance of Maintaining the Dental Air Compressor

The cleaner the air your compressor creates and uses, the safer your patients. In a dental practice, there is the risk of exposure to bacteria, microorganisms and pathogens. When equipment is producing poor-quality air, or it’s improperly generating a moist environment in machine parts, you could be creating a breeding ground for these dangers.

The filtration system is integral to the efficiency of an air compressor. As long as the air and oil are sufficiently filtered throughout a given cycle, the dental air compressor can be expected to produce cool air at consistent volumes with an overall smooth performance from the machine. However, if the filters are clogged with dirt, pressure drop can ensue, and this forces the air compressor to work harder just to perform basic functions. Consequently, energy gets consumed and parts get worn in the process.

If gunk and dirt are allowed to accumulate over several seasons, the decline in air quality could serve as a warning sign of costlier problems down the way with an air compressor. To prevent these problems from occurring in the first place, check the filters regularly and clean them out as needed.

Maintenance of an air compressor unit is only part of what keeps a compressed air system in optimal condition throughout the four seasons of a given year. In order to keep a well–functioning compressor performing up to par, you also need to ensure that the compressor room is maintained with optimal working conditions for the machinery contained within.

As with the air and oil filters within the air compressor, it’s important to check the ventilation for the room that houses the machine. To prevent the ambient air from becoming too congested, perform the following steps on a routine basis:

Check air vents for dust deposits.
Clear away dust buildup from air vents.
Inspect the HVAC system for dust buildup and defects.

In any kind of work environment, the air needs to circulate in order to remain healthy. Even if you have an HVAC system in place that’s been especially programmed to maintain suitable temperatures and ambient air quality inside the room that stores your compressed air system, the HVAC unit itself could become compromised if not subject to periodic inspections.

An air compressor is capable of working under all types of weather, providing that the compressor is kept in optimal shape and the operating environment is suited to the technology. With periodic maintenance of your compressed air system and its room of operation, you could enjoy optimal performance throughout the year with minimal downtime.

Dental Compressor

The Economics of Owning a Compressed Air System

Compressed air systems form the backbone of industrial manufacturing, are an essential component of medical facilities and are even responsible for keeping commercial food services running. Needless to say, many of the things that Americans have come to take for granted are only possible with the assistance of compressed air.

Compressed air systems provide consistent, responsive power to end-use applications. This power is essential for production plant operations who are looking to keep their employees productive while ensuring that they can complete operations safely and efficiently.

In many ways, the question of whether to replace or repair a compressed air system can be expressed as a mathematical problem. In other words, at which point does the money saved from a new system offset the cost of its purchase?

Luckily, many people have crunched the numbers on this question and have provided a nice basic framework for deciding which approach makes the most sense for your business.

According to PneumaticTips, it’s important to remember that, if you consider the overall cost of ownership of a compressed air system, assuming a ten-year life for the system, the purchase cost only accounts for about 12% of the total. Furthermore, 76% of the cost of owning a compressed air system comes in the form of electricity bills.
To put this in perspective, if you continuously run a 100-hp compressor at full power, you will spend $74,000 a year in energy costs, assuming a rate of 10 cents per kWh.

Therefore, if you are assessing the value of your compressed air system and making your decision in purely economic terms, you need to keep the total cost of ownership in the forefront of your mind. While the cost of repairs may be significantly less than the cost of replacing your system, ask yourself if you’re keeping a system working that’s actually costing you more in the long run by operating less efficiently.

These costs come in many different forms. First, as compressors age, the costs of repairs increase. That’s why you should carefully consider any repair that costs over 50% of the cost of a comparable replacement. But you also need to consider the operational inefficiencies and the subsequent costs of an older dental air compressor. Because of how inefficient some older models are, you may be wasting as much money on energy costs as you would spend on a new compressor.