What is a Compressed Air Audit and What are the Benefits?
A compressed air system won’t last forever, it has a usability lifetime. Perhaps it was fit for purpose when installed, but has compressed air usage changed since then? The maintenance necessary also becomes impactful the older the equipment becomes. Have you evaluated whether your compressed air system is still efficient, or is it unnecessarily driving up costs? Has your compressed air system still got what it takes, or is it wasting your money? Is it time for an air audit?
What is a compressed air audit and what are the benefits? Generating compressed air is costly; It also uses plenty of electricity. Some estimates suggest that around ten percent of manufacturing costs go into compressed air production. CO2 emissions and other environmental effects are also worth considering.
Anglian Compressors provides air audits to customers who already have a compressed air system installed. These audits offer varying levels of detail, from an initial visual inspection to an in-depth analysis tailored to your operational needs. There are several levels of testing, from an initial review to a detailed analysis, to properly assess how a system is performing. Then, following an initial review, a full air audit may be undertaken.
For industrial settings, an audit of compressed air systems usually more than pays for itself with the significant savings it achieves.
Table of Contents
Understanding the Need for a Compressed Air Audit
Compressed air is regularly used for industrial applications. Whether that’s in helping to package food ready for distribution, powering laser cutting machinery, producing plastic objects, or empty bottles, it’s surprising how frequently compressed air is needed in an industrial facility.
Although ambient air is free, converting it into compressed air is expensive and energy-intensive. Optimising this process is critical to minimising waste and costs.
While ambient air access nearby comes at no cost, producing compressed air is expensive, both from machinery costs and operational costs. Furthermore, the higher the pressure level required (measured in bar/PSI), the greater the energy cost. For example, every additional 1 bar (14.5 PSI) of pressure requires approximately 7% more energy to generate. Energy recovery systems can help offset some of these costs by utilising heat generated during the compression process.
In systems requiring pressures exceeding 15 bar, specialised air boosters are often integrated to achieve the necessary compression levels more efficiently.
Wasting energy through infrequent operations, air leaks within the system, flow rate inconsistencies, or air quality issues, adds up quickly. Each issue contributes to running longer, and often at a higher air pressure setting, to get pressurised air at the necessary level and flow rate.
Audits have uncovered significant inefficiencies, often revealing opportunities for savings in the tens of thousands of pounds over the lifespan of the equipment.
With busy operations, inefficient systems are easy to overlook. However, excessive utility costs due to energy waste, extra CO2 emissions, air leaks, and additional wear & tear on equipment shouldn’t be ignored. Many system audits surface cost implications in the tens of thousands of pounds over the lifetime of the installed equipment.
The Process of a Compressed Air Audit
A compressed air audit involves assessing the installation, equipment, nearby air quality, and other factors. A key metric is comparing the kilowatts (energy) consumed for every 100 cubic feet per minute (cfm) of compressed air produced.
Key elements examined include system dynamics (airflow, pressure, and energy consumption) and the equipment’s efficiency at delivering compressed air at the required levels.
- Audit Report: The findings are consolidated into a detailed report with recommendations, estimated costs for corrective actions, and projected cost savings.
- Site Survey: The audit starts with a site survey to assess the installed equipment, piping structure, and how each piece of equipment is intended to operate versus actual usage patterns.
- System Analysis: The dynamics of the system are analysed, focusing on airflow, pressure, cfm, and energy consumption. Additional tools, like iiTrak monitoring systems, may be used for detailed performance tracking over time.
The Different Levels of Compressed Air Audits
There are different levels of compressed air audits. We explain these below:
Level 1 – Free visual inspection on-site. The #airCHECK includes a visual inspection, air quality check, a review of ISO standards compliance, drainage check, checking for unproductive running, and air pressure levels vs. expectations and so on.Another small report often produced is the Energy Potential Calculation (EPC). This provides insight into what cost savings might be achievable. This free review intends to provide a first look at whether there are enough potential ways to save money to go on to level 2.
The Energy Potential Calculation (EPC) estimates potential cost savings from improving the system’s efficiency.
Level 2 – Our engineer may recommend adding the iiTrak monitoring system. This attaches to the existing equipment to track air usage and running hours for one week. From this data collection, the engineer extrapolates how the equipment is used in real terms, and whether it could be operated more efficiently. The engineer’s report considers whether optimal equipment is present, or if replacement equipment would offer lower operating costs, reduced energy expenditures, or other benefits, such as a cut in daily CO2 emissions, making it a net positive.
This advanced tool tracks air usage, operating hours, and efficiency for one week, identifying areas where energy or operational improvements can be made.
Level 3 – Complete AIRscan Audit. This is our most advanced audit, which complies with the ISO 11011 UK energy standard. Analysis of the data collected includes a dew and pressure point review, testing air quality, a review of compressed air processes (including the compressor room), flow rate determination, and air leak detection. While this is a paid service, in most cases, implementation of the audit’s recommendations provides sufficient cost savings for you to come out ahead. This comprehensive level often uncovers opportunities for savings exceeding the audit’s cost.
It includes air quality analysis, dew and pressure point testing, flow rate assessment, and leak detection, providing a comprehensive understanding of the system’s inefficiencies.
The Benefits of a Compressed Air Audit
Here are some of the key benefits of a compressed air assessment:
The Benefits of a Compressed Air Audit
Efficient systems contribute to sustainability goals by minimising energy use and CO2 output.
- Greater Energy Efficiency: Audits identify inefficiencies and recommend optimisations, such as installing Variable Speed Drive (VSD) compressors, to match supply to demand.
- Better System Reliability Leading to Less Downtime: Proactive recommendations help prevent unexpected failures, reducing costly downtime.
- Operating Costs are Lowered through New Efficiencies: Issues like air leaks, pressure drops, and clogged filters are identified and addressed, ensuring the system operates at peak performance.
- UK ISO Standards Compliance: Audits ensure systems align with the latest standards, improving operational credibility and safety.
- Reduced CO2 emissions: More efficient operations use less energy per 100 cfm, reducing CO₂ emissions significantly, which helps meet sustainability targets.
Real-world Case Studies
Case Study 1: Based on an iiTrak study performed, Fabricon Design Ltd decided to upgrade to a rotary screw air compressor system to feed into their CNC cutting equipment. This provided an estimated 51 percent reduction in energy usage, with a projected cost saving of £2479 annually.
Case Study 2: Following a compressed air audit, a major cement producer decided to upgrade to variable speed drive compressors. Along with an estimated 130+ tons of CO2 emission cuts, energy savings were expected to be £23,500 annually.
Conclusion
With ongoing technological advancements in compressed air systems, regular audits provide actionable insights into whether system upgrades or process improvements are necessary.
Compressed air audits ensure your system is cost-effective and environmentally friendly. By adopting a three-tier approach, businesses can achieve significant savings and operational improvements. With technological advancements, audits can identify when upgrading equipment is beneficial.
Take advantage of Anglian Compressor’s air audit services today to uncover potential cost savings and efficiency improvements.
A properly conducted audit is vital to assessing where inefficiencies are present in your compressed air system. Anglian Compressors’ air audit services can help you uncover potential improvements that save money while boosting efficiency.
Book your air audit today. Contact us below.