Why pressure matters
Compressing to a higher pressure takes more energy, and a higher pressure also pushes more air through every leak and open end. Excess pressure is often set as a safety margin and never reviewed.
Find the real requirement
Establish the minimum:
- The pressure each process or tool needs at the point of use
- The pressure drop across treatment and piping
- The pressure drop at peak demand
- Which single user sets the minimum and whether it can be treated separately
Lower it step by step
Reduce the setpoint in small steps while monitoring the processes, and confirm that every user still performs. Restore if there is a problem, and find out why before trying again.
Fix the cause of the margin
If a particular user needs high pressure, consider a local booster or a better supply to it, rather than raising the whole system. If pressure drop is the reason, address the piping or treatment.
Verify
Record power and pressure before and after under comparable demand. We do not quote a fixed saving per unit of pressure, because it depends on the system.
Starting data
To start, it helps to have:
- Compressor make, model, rated power and controls
- Operating pressure settings and the lowest pressure the processes need
- Operating hours and shift pattern
- Any existing power, flow or pressure records
Frequently asked questions
How much energy does lower pressure save?
It depends on the plant. It is measured on the actual compressor and demand, not assumed from a rule of thumb.
Is it safe to lower the pressure?
Yes if every user still gets the pressure it needs. Do it in steps and check the processes.
Why do my tools lose pressure at peak?
Pressure drop in piping, filters or hoses, or insufficient storage, are common causes. Measure at the point of use.