With the price of electricity rising rapidly and the focus on change, there is a need to implement measures that deliver immediate results. The solution to this thorny problem lies in energy conservation. With this in mind, an industrial compressed air audit is recommended.
What does it involve?
The compressed air audit is essential in industry. Indeed, compressed air can help to considerably improve the productivity and efficiency of an industry. As a reminder, it is obtained by using a compressor that will compress the air. The volume of the air will be reduced by the machine. This will increase the pressure in the new volume. In fact, the industrial compressed air audit is an efficient way to identify the energy consumption within the company and at the same time evaluate its compressed air needs. In addition to the industrial compressed air audit, specialists also recommend regular checks for air leaks. It is even possible to integrate this operation in the maintenance routines.
The main objectives of this audit
This compressed air report has several objectives. Firstly, it allows to locate and identify leaks. This makes it possible to classify them by category, i.e. by urgency of repair, importance, etc. This first objective also offers the possibility of estimating the repair and energy costs of these leaks. The managers can then know the profitability of these repairs and at the same time carry out their follow-up. The second objective of the industrial compressed air audit is to optimize the network. This includes the regulation of the installations, the operation of the compressors, and the dimensioning of the installations, in particular the looping to be planned, the tank to be installed, etc.
The third objective of the compressed air report is to verify the relevance of using compressed air in certain aspects of the process. In this context, it seeks to highlight abuses or energy aberrations. This means that the operation will serve to identify and quantify the equipment that is constantly leaking. This can lead to their questioning. The fourth objective of the compressed air audit is to make observations on the type of equipment used by the industry. Indeed, the energy efficiency of certain equipment may not be satisfactory. For example, the proper operation of a piece of equipment can lead to leaks, the flow of which is sometimes high. It is therefore possible to consider using other equipment to reduce these leaks. Finally, the fifth objective is to make recommendations for good practices.
How does this audit take place?
It should be noted that the compressed air audit can be simple or exhaustive, depending on the needs of the company’s managers. In order to conduct a successful compressed air audit, the first step is to select the compressors. The compressors can be regulated or fixed speed. The engineers will then place a data logging unit on each compressor in the industry network. This is done for a pre-determined period of time. The data logger will then capture all the necessary data and transmit it to a PC. The PC is responsible for drawing a diagram of the compressed air consumption.
This diagram will present various information useful for the industrial compressed air audit. This includes the no-load performance and the ratio of efficiency to compressed air consumption of each compressor. Also, the compressor on/off times and consumption variations are part of the data collected in this compressed air report. The results can be used to analyze the compressed air requirements or consumption of the industrial unit. It is also useful for determining the required compressed air flow. By comparing the different variants and calculating the cost effectiveness, the technician is able to determine which retrofit measures should be implemented. This may involve replacing part or all of the machines, or redesigning the machines. It is worth noting that, in some cases, this audit can reduce costs by up to 30%. To achieve this result, the specialists simulate various configurations of the compressed air system. This allows for realistic projections of potential energy savings.