If you make use of compressed air in your manufacturing or industrial processes, you will be aware that it is very costly to run. This is the reason why general air audits are so vital as they can help you optimise energy consumption and save money in the long run.
This article will cover the steps and process of a general air audit
- The first step in the audit will be an assessment of your system from the supply side and an evaluation of the condition, efficiency, and suitability of your current air compressors. This will determine its treatment, compressed air generation, and air distribution rate and if there are any operating energy costs to be had. It will also reveal if your unloading controls can operate a lower demand of airflow into a lower electrical usage and the capacity and condition of your equipment.
- Next will be an analysis of the demand side of the system, which could reveal some extensive energy-saving costs in terms of cabinet cooling, blow-off efficiency, diaphragm pump controls, and air-driven vacuum generators. Waste management on the demand side is often ignored, but any leaks will now be evaluated for size and system performance. Even a quarter-inch leak could mean a significant waste of electricity, so it is vital to have this audited. A good quality air audit will help you to implement an effective leak inspection program, and this generally involves maintenance staff inspecting all equipment areas once a month. Such leaks should be recorded, measured, and quantified in order to determine flow and a wastage cost.
- The third step in your air audit will be checking how you can operate the most efficiently at the lowest practical pressure. Any systems that are operating off unregulated air will have pressure spikes, and additional pressure translates to more airflow without an increase in production. If too many processes in your system are running at too high of a pressure, your quality and production will be negatively affected. This audit will help you to identify optimal, minimum flow rates, and the lowest effective pressure for your jobs.
- An air audit should also include checking if there are sufficient air-saving devices (e.g., air curtains and venturi nozzles) and if the compressor controls are being applied correctly.
- It should also reveal if you have the most suitable connectors, dryers, regulators, and filters and if your air receiver is in the right position.
- The final step in your air audit involves looking at both the supply and demand side as a whole. To perform optimally, the supply side must store and produce air at the maximum pressure possible. From a demand perspective, each process should be running at the lowest pressure for operational efficiency. This focus on interconnectivity optimizes compressed air energy costs and, when implemented, you could save up to 50 percent of demand and power costs immediately after your audit.