Compressed Air Audit is about ensuring adequate compressed air supply as paramount, but still how it can be optimized to reduce energy costs. A compressed air audit identifies how one can improve the compressed air system. As a part of these improvements there are additional benefits like reduction in unscheduled compressed air system downtime and wasted inputs, as well as improved control over product quality.
WHAT IS INVESTIGATED DURING A COMPRESSED AIR AUDIT?
Compressed air system audit analyzes :
Compressed air system demand: pressure, flow, system losses
Optimization of compressor operation
Level of Air Treatment - An air treatment level is selected based on the application and system components requirements.
Proper air quality saves a plant money be extending the service life of equipment and increasing system uptime. Poor air quality results in short component life increasing operating and maintenance costs.
Leaks - Identify and quantify leaks in the system and recommend a leak management program.
Controls - Evaluate the control system to see if an upgrade or modification will improve performance based on the system demand profile.
Piping System - The layout of the piping system is reviewed. Pressure drop and efficiency are measured and condensate removal is reviewed. Simple changes that can enhance system performance are suggested.
Artificial Demand - A common practice is to increase system pressure to meet compressed air need thus creating artificial demand. In our experience, 25 to 30% of the horsepower used to generate compressed air is a result of unnecessarily high system pressure. By analyzing the compressed air systems load profile a strategy can often be devised to reduce horsepower and wasted energy.
Many compressed air problems are caused by fluctuating pressure at point of use locations. These low air pressure fluctuations are often misinterpreted as a need for additional compressor capacity when a simple system redesign will remedy the problems. The capital cost of redesigning a compressed air system usually pales in comparison with continuing to operate inefficiently.
End-Use Equipment - The compressed air systems components are considered. When appropriate replacements and upgrades are recommended that offer cost savings. Equipment reviewed during the audit include: