A thorough survey of your compressed air system’s dynamics – including logging and analysis of the air net’s key parameters – helps determine the right operating balance while identifying your system’s energy savings potential. An air audit that evaluates both the supply side and demand side of a compressed air system can detect energy waste and capture an accurate compressed air profile for the plant. Available audits range from basic inspections to a full audit survey.
What are the differences between available audits?
Walking the line is the simplest of all procedures and is comprised of a visual inspection of the various components of the compressor system including but not limited to the compressor room, filters, piping and condensate drains. This audit can reveal inefficiencies or performance weaknesses, as well as identify areas for improvement.
Data logging uses a standard formula (one that includes power factor) to calculate the current (amps) and involves performance tracking of the compressor system for a minimum of seven days. Data logging also involves walking the line, as well as determining inappropriate uses of compressed air or inefficiencies in compressor room and plant floor layout. Data logging can reveal if the compressor is correctly sized or if it is operating close to its maximum capable CFM output.
A full system audit can include a range of in-depth audits on the various parts of the compressor system. Individual audits include air measurement of the compressed air system demand over seven days, air leak detection and control, air quality and assessment of water or oil in the air, a maintenance review which helps keep maintenance schedules current and the development of a monitoring and control program which sets out recommendations for long-term monitoring to maintain optimal efficiency. Often, the savings resulting from lower energy costs and higher production line efficiency pays for the investment in a full system audit.
Opportunities for Huge Savings
An energy audit can identify potential opportunities for energy recovery. With energy recovery, the heat byproduct of compressed air is reused in other processes such as heating water, instead of being diverted into the atmosphere. This is particularly useful in manufacturing plants that already need hot water for processes such as scalding, cleaning, sterilizing and steaming. Plus, when using recovered energy, the consumption of fuel can almost be completely offset.
When inefficiencies are discovered and corrected on the supply side, the performance on the demand side can be better evaluated to make sure the system has the correct sized compressors to match the demand. Then, once corrections are made on the demand side, real savings can be realized.
Audit Best Practices
Be sure to ask your audit provider what kind of report will be provided following the audit and find out whether or not the company offers a post audit or an annual PM check-up study. Also, ask if the company will help fix inefficiencies that are discovered during the audit. Most importantly, make sure the audit can be performed when the systems are running normally, ensuring that there is no need for any downtime.
Do you have questions about compressed air audits? Contact us or leave a comment below.
