What is Compressed Air Audit?
Compressed Air Audit detects inefficiencies in compressed air system & assists with practical air management processes, complete system performance optimization & leak reduction. Compressed Air Audit helps to identify opportunities for reducing energy consumption & overall business costs of their compressed air installations. It also helps customers to reduce power consumption, compressed air system load & wear, tear. This prolongs the life of the entire compressed air system.
Why a Compressed Air Audit?
Compressed air is widely used throughout industry & it is one of the most expensive utilities. It can be called the fourth utility after electricity, gas & water in operating cost. Around 30-40% compressor energy input loss are due to invisible air leakages. Sound operating practices & audit can reduce energy consumption by 20% to 50%.Compressed Air Audit is an accurate process undertaken to identify areas of inefficiencies within a system & provides detailed independently assessed & compiled reports providing information on: System optimization, Distribution, Risk assessment, Cost savings, Recommendations, Ongoing energy management plans.
Compressed Air audit is a flexible, diagnostic package for compressed air systems that allows customers to select any level of air audit required for their particular system. We provide variety of options for the Compressed Air audit, ranging from full system audits to specific measurements, such as leak detection, power & flow rate, etc.
Options for the Compressed Air Audit include:
Free air delivery of compressor, Air leakage test at compressor, Actual air leakage identification in plant, Feasibility check-up for VFD based compressor.
- Air measurement: An accurate account of your plants compressed air demand over a seven-day cycle, identifying energy costs & potential savings. Again, flow rates can be tested without interrupting service.
- Air leak detection & control: History has shown that leaks typically account for 20 % of the system demand. Consider that figure when examining utility costs across a month, a year or the life of the compressor.
- Air quality audit: Measures the quality of the air, including an assessment of any water or oil in the compressed air, & draws comparisons to your specific needs at any point in the system. Dirty air not only means frequent & costly filter cartridge changes, but it also threatens production quality & can lead to work interruptions or stoppages.
- Maintenance review: Assesses current service schedules & programs for effectiveness in the equipment, including compressors, filters, dryers & ancillaries.
- Monitoring & control program: Sets out recommendations for long-term monitoring & control to maintain optimum efficiency.
Where is the Savings Made?
Compressed air cost is recovered through reduced system costs over a short period of time.
- Supply Side: 10 - 20% of the savings are commonly found on the supply side of a compressed air system by identifying areas of improvement in equipment, Technology, Controls, Monitoring, Equipment maintenance, Installation issues.
- Demand Side: A further 20 to 30% of savings are commonly found on the demand side of a compressed air system by identifying areas of improvement in; Compressed air leaks, Artificial demand, System dynamics, System design, Monitoring & sub-monitoring.
Benefits of compressed air audit:
- Reduce artificial air demand
- Operate compressors at high efficiency
- Reduce the losses in filters, dryers
- Know the actual air delivered by compressor against design value
- Find out the volume of air leakage in the plant
- Identification of air leakage spots in the plant
From mining, lumber & paper mills, petroleum, chemical, textile & glass production to small manufacturing plants & hotels, compressed air provides critical services & can often represent the majority of the facility energy costs.