Why Do You Need a Compressed Air Audit?
Compressed air systems are integral to the day-to-day running of countless businesses in numerous industries. However, like all other industrial equipment, air compressors sustain wear and tear over time, losing efficiency. But it is not just time that can take its toll on your vital tools and equipment.
As businesses grow, their compressed air usage often changes. While your air compressor system might have been perfectly calibrated until a few years ago, it may no longer be running optimally if your requirements have changed. For example, you might have plugged new tools and equipment into your system without tweaking its settings and calibration for optimum efficiency.
Moreover, tiny inconsistencies in air pressure may now go unnoticed, but the extra electricity required to achieve the air pressure you desire could add up to a small fortune over the space of several months or years.
Fortunately, by hiring our experts for a compressed air energy audit, you can maximise the lifespan of your equipment while shaving a few zeros off your annual energy bill. You can also do your part to reduce greenhouse gas emissions, remain compliant with ever-changing regulations, improve workplace productivity, and much more. When it comes down to it, a compressed air audit will likely pay for itself in no time.
Below, we discuss the details of compressed air audits, including the need for a compressed air assessment, what they involve, their key benefits, and how to prepare. If you need specific advice regarding your existing system, do not hesitate to call us.
Understanding Compressed Air Audits
Compressed air is often referred to as the ‘fourth utility’, yet the overall system efficiency of a compressed air system is easily overlooked. Generating compressed air can be costly, especially when hidden problems such as air leaks, poor air pressure levels, or inefficient air dryers go unnoticed.
A properly conducted audit of compressed air systems examines both the supply side (compressors and dryers) and the demand side (piping, end-use tools, and the wider system) to improve performance. Using flow profiling and data loggers, we can monitor compressed air consumption across shifts to identify wasted energy and operational costs.
Audits often reveal issues like artificial demand, where systems operate at unnecessarily high pressures due to leaks or poor design. By providing a comprehensive system analysis and understanding of the system’s dynamics, an air audit may significantly reduce energy consumption, lower maintenance costs, and deliver long-term savings across your entire system.
We utilize advanced diagnostic tools, such as Atlas Copco’s AIRScan, to provide ISO 11011-certified assessments. This allows us to go beyond simple visual checks and deliver data-driven insights into your specific compressed air challenge.
Key Benefits of Conducting a Compressed Air Audit
A compressed air assessment can be a huge benefit to just about any business. Here are just some of the key advantages of a professional audit:
Increased Energy Efficiency
An audit can identify ways to improve the efficiency of your air compressor and find issues that may be causing your system to energy compressed air energy. Recommendations may include upgrading to a variable speed drive (VSD) compressor to better match air produced with actual demand.
Reduced Business Downtime
Many workplaces rely on their air compressors for a wide array of daily tasks. If your compressor has an issue, you may not be able to do your job – any amount of downtime can cause serious harm to your business. Call us for an audit, and we will catch small issues before they become costly problems.
Reduced Operating Costs
Increasing the efficiency of your system can translate into significant savings on your operating costs. As mentioned above, some businesses reduce their total energy expenditure by up to 50% following an audit. This is often achieved by identifying opportunities for heat recovery, where waste heat from the compressor is repurposed to heat water or facility spaces.
Reduced Greenhouse Gas Emissions
Keeping your systems in full working order can significantly reduce your C02 emissions, helping you do your part for the environment and meeting sustainability targets often highlighted by the Department of Energy.
UK Standards Compliance
Trust us to carry out your audit. You can feel confident that you will always remain compliant with ever-changing quality, safety and efficiency regulations, including ESOS (Energy Savings Opportunity Scheme) and ISO 11011 standards.
Why Do You Need a Compressed Air Audit
Common Issues Identified During Audits
Some of the most common issues found during a compressed air audit include:
Air Leaks
Air leaks in an air compressor can account for up to 50% of the system’s energy loss. They are often caused by poor maintenance, improperly installed connections, and general wear and tear. Using ultrasonic leak detection, we can pinpoint these invisible losses.
Inappropriate Pressure Settings
If your air compressor’s usage has changed, you might no longer have the air pressure settings appropriately optimised, which can lead to premature wear and tear and high energy bills.
Incorrectly Sized Equipment
If you are using dryers, filters, or compressors that are not the correct size for your compressor system demand, you may be spending much more than necessary on energy.
Contamination and Moisture Issues
Inadequate drying processes and poor air filtration can lead to contaminants like water, oil, and particles infiltrating the system and damaging your equipment — issues that can be uncovered through professional air quality testing air quality analysis.
The Audit Process – What to Expect
A compressed air system audit is a detailed assessment designed to comprehensively understand your system’s performance and efficiency.
Our audit team starts by reviewing your site layout, compressor room setup, air dryers, piping, and end-use applications. We gather key information such as system pressure, current energy use, and maintenance records to build a clear picture of your system dynamics.
We then install data loggers to monitor airflow rates, pressure levels, power consumption, and air use over time. This approach captures how your system operates during different shifts, ensuring a true reflection of your energy usage rather than a single snapshot. For continuous monitoring, we may recommend SMARTLINK technology, which provides real-time data on your system’s health.
The system assessment audit covers both the supply side (compressors, dryers, filters) and the demand side (piping, tools, end uses), allowing us to uncover hidden issues like pressure drops, artificial demand, and leaks. We also carry out air leak detection and air quality checks where needed.
After collecting and analysis of the data, we deliver a detailed report highlighting key findings, areas for improvement, and potential energy savings. Our tailored recommendations aim to help you reduce energy consumption, lower operational costs, and improve the reliability of your entire compressed air system.
How to Prepare for a Compressed Air Audit
Depending on your unique situation, we will let you know exactly what we need to perform your compressed air measurement and audit as efficiently and effectively as possible. However, it will be a great help if you can provide us with documentation such as your system manuals, maintenance logs, and energy usage data. You can also help speed things up by ensuring we can easily access all your equipment, including the piping, end-use points, and compressors.
Book Your Compressed Air Audit Today
At Seach Air, we have been at the forefront of the compressed air industry for over 75 years. We have also been a premier distributor for Atlas Copco since 2001 – and we were named Atlas Copco Compressor’s Distributor of the Year in 2022. If you want a team of highly experienced experts with a proven track record to perform your compressed air audit energy audit, you have come to the right place. As your local compressed air specialists, we are ready to assist. So, contact us today to book an audit our air audit services at a time that works with your busy schedule.
Frequently Asked Questions
What is involved in a compressed air system audit?
A compressed air system audit provides a comprehensive assessment of your supply and demand sides, covering compressors, air dryers, piping, and end-use equipment. It often includes the use of data loggers, air quality checks, air leak detection, and a detailed system dynamics analysis to identify ways to improve system efficiency and reduce energy consumption.
How can a compressed air audit reduce operational costs?
By providing a comprehensive understanding of your system’s performance and energy use, an air audit can uncover hidden issues such as artificial demand, pressure drops, and inefficient air production. Correcting these problems can lead to significant cost savings, lower maintenance costs, and improvements in system reliability.
Why should regular audits be part of compressed air maintenance?
Regular audits ensure you can effectively track changes in compressed air demand, monitor system pressure, and ensure the efficient compressed air production required for your operations. A properly conducted audit helps reduce energy costs, improve system performance, and extend the lifespan of your compressed air equipment.
What are the benefits of a compressed air audit?
The primary benefits of a compressed air audit include identified energy savings, improved system reliability, reduced downtime, and compliance with environmental regulations like ESOS.