compressed air system audit- Compressed air accounts for over 40% of a manufacturing facility’s total energy expenses, making an efficient compressed air system essential for a healthy bottom line. Unfortunately, not all systems are as efficient as they might be, and we see it all the time — compressors that aren’t the right size, old technology, air leaks, pressure dips – the list goes on and on.
Rising energy costs are a significant source of anxiety. According to the Department of Energy, more than half of industrial air compressors are inefficient, resulting in 3.2 billion dollars in energy loss per year. The good news is that factories that focused resources on cutting energy expenses were able to save up to 15% yearly with a payback of fewer than two years.
So you’d want to conduct a compressed air system audit. Congratulations on taking such a significant step! Measuring your compressed air system is an excellent method to begin understanding the expenses involved with your system — as well as the issues you face in terms of efficiency, pressure, air quality, and dependability.
So, how can you ensure that your plant’s compressed air system is efficient?
compressed air system audit – Uncover the Health of Your System
The first step in discovering faults that may be obstructing your unit’s efficiency and unnecessarily raising energy expenses is to conduct a compressed air system audit of your system. A compressed air system audit may be done on three levels: a walk-through assessment, a system assessment, or a full system audit.
Walk-through Evaluation
This procedure takes 12 to 2 days and includes a review of the plant’s compressed air system, as well as an examination of the distribution system for leaks, pressure drops, and compressor sizing issues. The compressed air system will be diagrammed, and a report with results and recommendations will be presented. (compressed air system audit)
System Assessment
A system assessment, which includes a walk-through as well as measurements gathered to determine system dynamics, is offered for a more detailed analysis. Pressure and demand profiles will be included in the compressed air system mapping. At the completion of the evaluation, the report’s findings and suggested remedies will be delivered.
Full System Audit
The system audit is the most thorough examination and takes 3 to 10 days to complete with minimal to no impact on present operations. Audits of compressed air systems in their whole include the following:
- Energy usage data logging – logs the energy the air compressors are consuming.
- Air measurement – identifies a factory’s true compressed air demand and operating schedule.
- Air leak detection & control – identify how much air is being lost due to leaks.
- Air quality – measures the number of particulates in the air system such as water and oil.
- Maintenance review – assesses the effectiveness of the current maintenance plan.
- Monitoring & control program – makes recommendations to maintain optimum efficiency.
Manufacturing Benefits of an Air Audit
Manufacturers who use compressed air in any industry – food and beverage, automotive, textile, power, electronics, and plastics, to name a few – will frequently discover that a compressed air system audit will pay for itself. Manufacturers can expect improvements in energy efficiency, system dependability, and lower operating costs based on the audit results.
During an audit, for example, some firms discover that their plant air systems operate at a greater pressure than the plant’s actual demand owing to pressure dips, air leaks, or excessive bends in pipe design. If a factory wants 100 psi but must create 120 psi owing to air loss, they are squandering 20 psi. An audit of your system might help you uncover sources of energy waste like this.
Inspect yourself before calling for help
Before booking an air audit, conduct your own examination to better understand how the compressor technology you’re using may be contributing to your energy expenditures. Following receipt of your data, you may choose to obtain a more detailed cost analysis of your present compressed air system.
If you’re hiring someone to handle the task, here are some critical pre-audit measures to take:
Gather nameplate information
The compressed air system auditor will be interested in the type of compressed air equipment you have installed. Take photographs of the equipment and document the data, equipment nameplates, and controls of all compressors, dryers, filters, and flow controllers. Identify any flow and power meters you have. Make a schematic of the equipment in your compressor room’s connections. Find the plant’s plumbing schematics. (compressed air system audit)
Estimate your operating hours
The operational hours are factored into the annual energy expenses. The auditor will want to know how long your compressed air system runs every week – and if this schedule fluctuates throughout the year due to seasons, product demand, holidays, plant shutdowns, and other factors.
Identify your critical demands
There will be some crucial demands in the plant that necessitate the maximum pressure, as well as a pressure level below which manufacturing gear begins to malfunction. Find out what these are and where they are so that the auditor can properly measure your system. Compressed air needs that require substantial quantities of compressed air on a regular basis are also essential. These are critical to quantify during a compressed air system audit. (compressed air system audit)
Make a list of your problems
The auditor must be aware of the issues that are afflicting your system. This is most likely why you called them in the first place. A list like this provides the auditor with crucial information for determining the core cause of the problem.
Communicate your future plans
If you want to install advanced compressed air-consuming equipment, it is best to notify the compressed air system auditor ahead of time so that they can make the appropriate suggestions. He or she will next decide whether or not your system is capable of handling increased flows and, if not, what steps to take. If necessary, systems can be designed to support the installation of new compressor capacity.
Gather your maintenance costs
The cost of running a compressor includes more than just energy. Other expenditures, including leasing, maintenance, consumables, maintenance contracts, and other goods, might account for a sizable portion of the total cost. Establish a detailed breakdown of all your expenditures to assist you to make the business case for change.
Choose your auditor
Choose your compressed air system auditor with care. Make sure you realize that certain free audits may not be worth the cost and may simply be aimed to sell you a new compressor. It is ideal to use a business that does not benefit from selling compressors, or if they do, a company that always conducts its audits on a product-neutral basis while looking at the entire compressed air system (check their references). It is critical that they not only test things in the compressor room but also go out into the plant and uncover possible inefficient compressed air uses and leaks. The majority of the savings come from lowering the end uses of compressed air.