Manufacturing plants spend about 40% of their total energy costs on compressed air. This translates to huge costs. However, this can be prevented through the efficient maintenance of your compressed air system.
One way to do this is through a compressed air audit. This process can help you determine the problems faced by your system leading to this surge in energy costs. To learn more about how it can help you save on operating costs, here are the things you need to know about compressed air audit.
What is Compressed Air Audit?
A compressed air audit’s goal is to help preserve your air compressor system and identify a way on how you can save on operating costs.
It is done by certified technicians who review your compressed air system and calculate processes to operate the system more productively. These technicians can also help identify current issues on your system and suggest adjustments that can be made.
Types of Air Audit
A compressed air audit has three different levels that can be conducted in your own system.
1. Walk-through Evaluation
A walk-through evaluation process involves an examination of your air compressor. It includes an inspection of issues in the system such as pressure drops or leaks. This process is usually done in a short amount of time and can take between ½ to 2 days.
2. System Assessment
A system assessment is a more extensive review of your air compressor. It is done by combining walk-through and comprehensive readings in order to help you identify compressed air system dynamics. This process also presents pressure and demand profiles of your air compressor and provides a conclusion of the findings.
3. Full System Audit
A full system audit is the most comprehensive survey of your air compressor system. As a result, this process takes longer at about 3 to 10 days. It includes the following:
- Air leak detection & control – This determines how leaks can affect the large amount of lost air.
- Air measurement – This identifies the demand and operating schedule of compressed air used by a factory.
- Air quality – This calculates the amount of particulates including oil and water in an air compressor.
- Energy usage data logging – This records how much energy a compressed air system consumes.
- Monitoring & control program – This suggests a proposal on how to preserve efficiency on an air compressor system.
- Maintenance review – This evaluates how effective an air compressor’s current maintenance plan.
Common Problems of Air Compressor Systems
It’s important to be aware of the common problems faced by your system to ensure your processes stay at optimum efficiency.
1. Air Leaks
According to studies, manufacturing facilities lose about 30% to 50% of their produced compressed air to leaks. This is one of the most common problems faced by industries.
A compressed air audit is essential to solve this problem and reduce the large costs spent on energy needed to run the air compressor.
2. Air Requirements
A compressed air system cannot operate effectively if the production overestimates the amount of air it requires. A facility should not define their own compressed air requirements at any amount of pressure whenever they want.
3. Air Restrictions
The significant loss of pressure in your air compressor can negatively impact the reliability of your system. This happen due to air restrictions such as blocked filter elements, abandoned separator cartridges, and obstructed manual drain traps.
4. Excessive Pressure
In order to combat the pressure loss, some industries put excessive pressure on their air compressor hoping to settle the issues. However, overpressurization is bad for your system as it increases leak which eventually leads to waste of money. It also has a negative effect on airflow.
5. System Maintenance
Ignoring the recommended system maintenance that your air compressor needs can lead to poor air quality. This can have an effect on your overall facility operations. That’s why it’s important to maintain necessary equipment like filters, driers, and separators to achieve dry and clean air.
6. Poor Piping
Loss of pressure in your air compressor is a result of bad piping. This includes old pipes, convoluted pipes, and even pipes with incorrect sizes. To resolve this issue and obtain efficiency, replace the poor section of the pipe with a new, high-quality one.
Have a business in the Philippines? CompressTech provides flexible and reliable piping systems for your facility. With 34 years of experience in the industry, CompressTech only provides high-quality compressed air products. Contact us today to know more.
A compressed air audit is an important step you must take to ensure the quality and effectiveness of your air compressor. Ultimately, this will help you avoid spending money on unnecessary costs due to problems in your system.
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