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Compressed air audits Manufacturing plants spend over 40% of their entire energy expenses on compressed air alone, making an efficient compressed air system essential for sustaining a healthy bottom line. But, unfortunately, not all systems function in the most efficient manner possible. The list is endless as we observe daily – compressors that are not correctly sized, obsolete technology, air leaks, pressure decreases.

Rising energy costs are a significant source of anxiety. For example, according to the US 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 those firms in this research who focused resources on cutting energy expenses could save up to 15% yearly with fewer than two years of payback.

So, how can you ensure an efficient compressed air system at your plant? 

Compressed Air Audits – Uncover the Health of Your System 

The first step in discovering faults that may be impeding your unit’s performance and unnecessarily raising energy expenses is to do a compressed air audit on your system. Compressed air audits may be done at three levels: walk-through assessment, system assessment, and complete system audit.

Walk-through Evaluation

This procedure usually takes 12 to 2 days. It involves assessing the plant’s compressed air system and an examination of the distribution system to look for leaks, pressure dips, and compressor sizing concerns. A map of the compact air system will be created, and a report of findings and remedies will be provided.

System Assessment

A system assessment is provided for a more detailed analysis, which includes a walk-through and measurements gathered to determine system dynamics. Pressure and demand profiles will be included in the compressed air system mapping. The report’s findings and potential remedies will be supplied after the conclusion of the evaluation.

Manufacturing Benefits of compressed air audits

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 audit will pay for itself. Manufacturers can expect improvements in energy efficiency, system dependability, and lower operating costs based on the audit results.

For example, owing to pressure drops, air leaks, or excessive bends in pipe design, some manufacturers discover that their plant air systems operate at a more significant pressure than the actual demand of the plant during an audit. For example, if a factory wants 100 psi but must create 120 psi due to air loss, they squandered 20 psi. An audit of your system can assist you in identifying sources of energy waste such as this.

Conduct a Site Survey along with compressed air audits

Before installing any measuring devices, it is critical to list and comprehend all of the equipment in a compressed air system so that 1) the instruments are appropriately located and 2) the system dynamics are well understood. The person in charge of gathering information should take note of the following: environmental conditions, physical layout, and specifics on all air system components, including clean air treatment, piping, storage, and controls. Processes at the facility should be recorded as well. Many auditors will have a questionnaire to fill out to consolidate the information into a single document.

Measure and Quantify compressed air audits

Power, flow, and pressure should be monitored over 10 days in various systems to produce an accurate system snapshot (other data points such as pressure dew point [to determine air quality], vacuum, and temperature should be measured as needed based on system requirements). To detect non-productive demands, the assessment period should cover nights, weekends, or another downtime.

True power utilised by air compressors is measured using kilowatt metres, which monitor amperage, voltage, and power factor. Data loggers should capture data points on each air compressor every 0.5 seconds and average the data over a predetermined recording time, such as a 20-second resolution.

Understand the System Dynamics of compressed air audits

The obtained system information should be properly evaluated, and opportunities for improvement should be identified. To reduce the compressed air system’s energy consumption, many scenarios should be evaluated, including an examination of the facility’s primary compressed air users to establish whether compressed air is the most efficient alternative for each application.

Implement Recommendations to Improve compressed air audits

Many system analyses focus on minimising compressed air use by repairing compressed air leaks or eliminating “inappropriate compressed air applications.” Engineered air nozzles, for example, can be used to replace perforated pipe in blow-off applications, reducing compressed air usage. On the other hand, real energy savings will be obtained ONLY if the controls on the air compressors can capitalise on these benefits, which may involve the right usage of a variable frequency drive when appropriate (VFD).

Almost seldom are the expenses associated with modifying compressor settings factored into ROI estimates. Within a wide range of compressed air flows, many modulating air compressors will continue to utilise the same amount of power (kW) (cfm). Thus, users cannot expect a linear relationship between compressed air use and electricity consumption.

Verify Performance post compressed air audits

Utility rebate programmes may demand additional compressed air audits after adjusting the air system to verify energy savings. Even if utility rebates do not demand this verification level, facilities should consider undertaking some post-optimization review. All plans, including those developed using air audit data and freshly installed systems, may be improved.

The extra examination should confirm the findings of the compressed air audit and aid in identifying other areas for improvement. Because certain system controllers capture and retain continuous energy usage data, a review with a master system controller gives adequate information for internal evaluation. It may be used to evaluate improvement metrics for many. visit our site stopleakloss