Inefficiencies can lead to significant losses in large-scale operations, especially when it comes to poorly maintained or energy-inefficient equipment. Often overwhelmed with day-to-day responsibilities, operations managers need a clear starting point to evaluate and enhance their current air compressor systems. This is where a compressed air audit becomes invaluable.
A compressed air audit offers a comprehensive review of your entire compressed air system, pinpointing areas for improvement to reduce waste, boost energy efficiency, and potentially enhance productivity. An audit can lead to increased reliability and reduced downtime by identifying necessary changes.
Table of Contents
Understanding Compressed Air Audits
Air audit services are intended to improve the overall efficiency of your system. The benefits of a compressed air audit should surpass the expense by a considerable margin.
Air audits are important because they entail a systematic review of your entire air compressor system, including air boosters, and other equipment. Inefficiencies are identified, along with recommended steps for improvement.
In some cases, your operations manager or other personnel can handle these internally. In other cases, an air specialist like J LL Leach is well-positioned to deliver value-added solutions.
A comprehensive leak detection review can find numerous air leaks. This is not uncommon, especially with older air compressor systems. Financial losses resulting from air pressure leaks are considerable. These include producing extra air to mitigate the leakage losses, extra wear on equipment when doing so, and additional energy usage.
Overworked air systems affect system reliability. Industrial facilities will not necessarily connect air leakage with declining system performance. However, a whole system review isolates less obvious causes through a detailed analysis of the data. Our team then identifies areas for improvement and makes recommendations to boost performance and efficiency.
A full review may include, but is not limited to:
- Conducting a complete air audit to obtain a clear picture.
- System analysis audit to identify weak points or gaps, including controls and overall design.
- Energy vs production: looks at how much energy (kilowatts) is used to produce a standard quantity of compressed air (100 cubic feet per minute).
- Measurement of air settings relative to current output.
- Total airflow expectation vs current reality.
- Air leak detection throughout the entire compressor system.
- Analysis of air quality and whether it is clean enough for your requirements (present and future). If not, what filtration or other recommendations are advisable?
- Distribution systems analysis, especially the piping structure, includes looking for pipes with rust and scale.
Key Benefits of Conducting Compressed Air Audits
There are many meaningful benefits to arranging a compressed air audit of your air systems.
Here are a few of them:
Energy Efficiency: compressed air systems use a lot of energy, so any efficiency improvements are incredibly worthwhile. When conducting a detailed examination of the existing system, ask, ‘What air should be produced vs the energy cost to do so?’ Equipment updates are recommended where significant efficiencies are not possible with existing equipment.
Reducing Expenditures: reviews how to reduce costs without affecting air production. This includes stopping air leakage losses, fixing pipe distribution issues, and reconfiguring controls to maximise performance. Different approaches are considered to save money while still meeting air production needs.
System Reliability: air audits discover potential early equipment failure indicators before they occur. Pre-emptive parts replacement avoids costlier repairs and downtime. Poorly organised and badly configured systems are analysed to fix teething issues and increase system reliability. Areas like pressure drops, dirty air, and clogged filters are all checked and reported on.
Environmental Considerations: better energy efficiencies result in less pollution. Companies must comply with environmental ISO standards. This especially applies to waste disposal, e.g. condensate. Various equipment, such as oil/water separators, is useful and may be recommended as a future upgrade.
Contact us to discuss air audit benefits and what J Ll Leach can offer you.
Case Studies and Real-World Examples
Below are a couple of examples of successful air audits:
A sizable cement manufacturer was considering upgrading its air compressors. A compressed air audit highlighted the benefits of moving away from their ageing compressors to newer variable-speed drive compressors. Rather than being fixed at a single speed, variable-speed drive compressors are built to allow for quick speed adjustments to accommodate changing air production requirements.
The air audit and subsequent upgrades removed over 120 tons of future emissions and reduced their energy bill by over £22,000 a year.
In another successful air audit, a fabrication company requested an iiTrak audit analysis – this is an audit carried out using Atlas Copco iiTrak software and monitoring equipment to establish energy usage over a predetermined time. This confirmed that their CNC equipment would benefit by replacing their existing air compressors with new Atlas Copco variable speed drive machines.
When completed, they realised over 50% energy savings with cost reductions of over £8,400 each year.
How to Prepare for a Compressed Air Audit
Here are some steps to take in preparation for a compressed air audit:
Clean the area: review the area to ensure it is clear of debris. Check that it is as accessible as possible. Remove any objects that do not need to be there.
Ensure access: verify that all components and parts within the system are accessible for review.
Locate all documentation: collate all air system documentation for review. This includes product manuals, system procedures, and other company information including your current electricity rates so that the analysis can be carried out.
Prepare site approval: complete any security approvals or other necessary actions ahead of time. Assign a member of staff responsible for the audit team to meet them upon arrival and stay with them.
Make staff aware: let employees know that there may be limited disruption to normal activities during the air audit.
Pitfalls to Avoid
Do not overlook problematic, difficult-to-access system areas where air leaks are possible. Clear access to them for review – this is helpful but not essential as our equipment allows analysis from a distance without having to be in close proximity to the leak.
All air system equipment needs periodic auditing!
Conclusion
A compressed air audit is essential to get the most out of your equipment. Air systems are not inexpensive to operate, so regularly auditing them ensures inefficiencies are wrung out of the system. This will reduce energy usage, ensure consistency, avoid waste, and allow you to remain eco-friendly.
Ensure your equipment helps you to stay competitive. Contact us today to learn how we can help you.
