Contact Information

Illinois

108 Gateway Road, Bensenville, IL 60106
Telephone: (630) 766-7900
Fax: (630) 766-7937

Wisconsin

7528 Pershing Blvd., Suite B300, Kenosha, WI 53142
Telephone: (800) 323-8162
Fax: (630) 766-7937

Electronic mail:

Sales: sales@airservicesco.com
Webmaster: webmaster@airservicesco.com

Useful Data

Breakdown of Compressed Air Costs over 10 Years
Breakdown of Typical Plant Air Consumption
Compressor Control Comparison
% Of Full Load BHP Versus % Of Full Load Capacity
% of
Compressor
Capacity
Modulation
(Inlet Valve)
% FL BHP
Variable Displacement
(Geometry)
% FL BHP
On-Line / Off-Line

Variable Speed Drive
1 Gal/CFM
3 Gal/CFM
5 Gal/CFM
% FL BHP
% FL BHP
% FL BHP
% FL BHP
100
100.00
100.00
100.00
100.00
100.00
100.00
95
98.50
96.00
101.51
100.49
99.95
95.20
90
97.00
92.00
100.44
98.36
97.28
90.40
85
95.50
88.20
99.28
96.11
94.51
85.60
80
94.00
84.70
98.02
93.71
91.61
80.80
75
92.50
81.50
96.64
91.17
88.59
76.00
70
91.00
78.30
95.12
88.46
85.43
71.20
65
89.50
75.40
93.45
85.57
82.10
66.40
60
88.00
73.00
91.58
82.49
78.63
61.60
55
86.50
70.80
89.49
79.19
75.02
56.80
50
85.00
69.00
87.13
75.67
71.25
52.00
45
83.50
64.60
84.44
71.89
67.34
47.20
40
82.00
60.20
81.35
67.80
63.28
42.40
35
80.50
55.80
77.76
63.41
59.06
37.60
30
79.00
51.40
73.53
58.76
54.69
32.80
25
77.50
47.00
68.51
53.84
50.15
28.00
20
76.00
42.60
62.48
48.65
45.46
23.20
15
74.50
38.20
55.19
43.17
40.60
18.40
10
73.00
33.80
46.26
37.41
35.57
13.60
5
71.50
29.40
36.19
31.36
30.37
8.80
0
70.00
25.00
27.33
26.30
26.09
4.00
Sample power cost numbers
Single shift operation / 10 hours per day / 5 days per week / $0.05 per kw

HP
Full load power cost
70% load
70% load
70% load
50% load
50% load
50% load

modulation
On-Line / Off-Line
Econotrol
modulation
On-Line / Off-Line
Econotrol
50
5,759.00
5,241.00
5,478.00
N/A
4,895.00
5,018.00
N/A
75
8,013.00
7,291.83
7,628.38
6,274.18
6,811.05
6,981.73
5,528.97
100
10,776.00
9,806.16
10,258.75
8,437.61
9,159.60
9,389.13
7,435.44
125
13,619.00
12,393.29
12,965.29
10,663.68
11,576.15
11,866.23
9,397.11
150
17,242.00
15,690.22
16,414.38
13,500.49
14,655.70
15,022.95
11,896.98
200
21,758.00
19,799.78
20,713.62
17,036.51
18,494.30
18,957.75
15,013.02
250
27,390.00
24,924.90
26,075.28
21,446.37
23,281.50
23,864.91
18,899.10
300
33,249.00
30,256.59
31,653.05
26,033.97
28,261.65
28,969.85
22,941.81
Variable speed units

70% Power Cost
50% Power Cost

160HP
11,754.60
8,139.30

100HP
7,362.00
5,265.00

67HP
4,978.00
3,528.00

Sample power cost numbers
Three shift operation / 24 hours per day / 7 days per week / $0.05 per kw
HP
Full load power cost
70% load
70% load
70% load
50% load
50% load
50% load

modulation
On-Line / Off-Line
Econotrol
modulation
On-Line / Off-Line
Econotrol
50
19,404.00
17,658.00
18,457.00
N/A
16,493.00
16,907.00
N/A
75
26,997.00
24,567.27
25,701.14
21,138.65
22,947.45
23,522.49
18,627.93
100
36,306.00
33,038.46
34,563.31
28,427.60
30,860.10
31,633.42
25,051.14
125
47,740.00
43,443.40
45,448.48
37,380.42
40,579.00
41,595.86
32,940.60
150
58,093.00
52,864.63
55,304.54
45,486.82
49,379.05
50,616.43
40,084.17
200
73,307.00
66,709.37
69,788.26
57,399.38
62,310.95
63,872.39
50,581.83
250
92,283.00
83,977.53
87,853.42
72,257.59
78,440.55
80,406.18
63,675.27
300
112,025.00
101,942.75
106,647.80
87,715.58
95,221.25
97,607.38
77,297.25
Variable speed units

70% Power Cost
50% Power Cost

160HP
39,495.46
27,348.05

100HP
24,886.00
17,740.00

67HP
16,771.00
11,887.00

Cost of Air Leaks

Single shift operation / 10 hours per day / 5 days per week / $0.05 per kw
1/4" air leak at 100PSI consumes approximately 104CFM - which comes to a yearly power cost of $2,235.00
1/2" air leak at 100PSI consumes approximately 415CFM - which comes to a yearly power cost of $8,483.00

Cost of Air Leaks

Three shift operation / 24 hours per day / 7 days per week / $0.05 per kw
1/4" air leak at 100PSI consumes approximately 104CFM - which comes to a yearly power cost of $7,530.00
1/2" air leak at 100PSI consumes approximately 415CFM - which comes to a yearly power cost of $28,580.00

Breakdown of Compressed Air Costs over 10 Years Breakdown of Typical Plant Air Consumption Compressor Control Comparison % Of Full Load BHP Versus % Of Full Load Capacity
% of Compressor Capacity	Modulation (Inlet Valve) % FL BHP	Variable Displacement (Geometry) % FL BHP	On-Line / Off-Line			Variable Speed Drive
			1 Gal/CFM	3 Gal/CFM	5 Gal/CFM
			% FL BHP	% FL BHP	% FL BHP	% FL BHP
100	100.00	100.00	100.00	100.00	100.00	100.00
95	98.50	96.00	101.51	100.49	99.95	95.20
90	97.00	92.00	100.44	98.36	97.28	90.40
85	95.50	88.20	99.28	96.11	94.51	85.60
80	94.00	84.70	98.02	93.71	91.61	80.80
75	92.50	81.50	96.64	91.17	88.59	76.00
70	91.00	78.30	95.12	88.46	85.43	71.20
65	89.50	75.40	93.45	85.57	82.10	66.40
60	88.00	73.00	91.58	82.49	78.63	61.60
55	86.50	70.80	89.49	79.19	75.02	56.80
50	85.00	69.00	87.13	75.67	71.25	52.00
45	83.50	64.60	84.44	71.89	67.34	47.20
40	82.00	60.20	81.35	67.80	63.28	42.40
35	80.50	55.80	77.76	63.41	59.06	37.60
30	79.00	51.40	73.53	58.76	54.69	32.80
25	77.50	47.00	68.51	53.84	50.15	28.00
20	76.00	42.60	62.48	48.65	45.46	23.20
15	74.50	38.20	55.19	43.17	40.60	18.40
10	73.00	33.80	46.26	37.41	35.57	13.60
5	71.50	29.40	36.19	31.36	30.37	8.80
0	70.00	25.00	27.33	26.30	26.09	4.00

Sample power cost numbers
Single shift operation / 10 hours per day / 5 days per week / $0.05 per kw
HP	Full load power cost	70% load	70% load	70% load	50% load	50% load	50% load
		modulation	On-Line / Off-Line	Econotrol	modulation	On-Line / Off-Line	Econotrol
50	5,759.00	5,241.00	5,478.00	N/A	4,895.00	5,018.00	N/A
75	8,013.00	7,291.83	7,628.38	6,274.18	6,811.05	6,981.73	5,528.97
100	10,776.00	9,806.16	10,258.75	8,437.61	9,159.60	9,389.13	7,435.44
125	13,619.00	12,393.29	12,965.29	10,663.68	11,576.15	11,866.23	9,397.11
150	17,242.00	15,690.22	16,414.38	13,500.49	14,655.70	15,022.95	11,896.98
200	21,758.00	19,799.78	20,713.62	17,036.51	18,494.30	18,957.75	15,013.02
250	27,390.00	24,924.90	26,075.28	21,446.37	23,281.50	23,864.91	18,899.10
300	33,249.00	30,256.59	31,653.05	26,033.97	28,261.65	28,969.85	22,941.81
Variable speed units
	70% Power Cost	50% Power Cost
160HP	11,754.60	8,139.30
100HP	7,362.00	5,265.00
67HP	4,978.00	3,528.00

Sample power cost numbers
Three shift operation / 24 hours per day / 7 days per week / $0.05 per kw
HP	Full load power cost	70% load	70% load	70% load	50% load	50% load	50% load
		modulation	On-Line / Off-Line	Econotrol	modulation	On-Line / Off-Line	Econotrol
50	19,404.00	17,658.00	18,457.00	N/A	16,493.00	16,907.00	N/A
75	26,997.00	24,567.27	25,701.14	21,138.65	22,947.45	23,522.49	18,627.93
100	36,306.00	33,038.46	34,563.31	28,427.60	30,860.10	31,633.42	25,051.14
125	47,740.00	43,443.40	45,448.48	37,380.42	40,579.00	41,595.86	32,940.60
150	58,093.00	52,864.63	55,304.54	45,486.82	49,379.05	50,616.43	40,084.17
200	73,307.00	66,709.37	69,788.26	57,399.38	62,310.95	63,872.39	50,581.83
250	92,283.00	83,977.53	87,853.42	72,257.59	78,440.55	80,406.18	63,675.27
300	112,025.00	101,942.75	106,647.80	87,715.58	95,221.25	97,607.38	77,297.25
Variable speed units
	70% Power Cost	50% Power Cost
160HP	39,495.46	27,348.05
100HP	24,886.00	17,740.00
67HP	16,771.00	11,887.00