Compressed Air System Audits
A compressed-air audit evaluates how your facility produces, treats, distributes and uses compressed air. We review your operating concerns and discuss the measurements needed to investigate pressure problems, changing demand and unnecessary energy use. The findings can help your team prioritize maintenance, piping, controls or equipment improvements. The recommended work and potential savings depend on what the assessment reveals.
The problems associated with operating a modern compressed air system are fairly complex and often camouflaged to the untrained eye. At the same time, many companies have cut back the internal resources dedicated to defining and solving those problems. That's where a professional Air Audit can help by addressing the total process of producing compressed air... not just the compressors. It's about taking compressed air, looking at it as your fourth utility, and making compressed air as dependable as your electric, water and gas services.
A true air audit will help plant operators optimize their systems and often result in turning off compressors, leading to higher efficiencies. In the past you asked compressor manufacturers, like Bobcat, to build the best engineered, most reliable, energy-efficient air compressors in the industry. But in today's global business climate, you need more than great equipment to survive and thrive. To drive operational excellence, we must go beyond the components of an air system and find solutions to the operating issues every air consumer faces.
Before requesting an audit, gather your compressor and dryer details, production schedule, available operating data and a brief description of the problem. Tell us when pressure drops occur, whether demand has changed and what your team has already checked. Contact us at (615) 641-3100 to discuss the scope of the assessment and the information needed to evaluate your system.
Contact Us For A Quote Or Service
Compressed Air System Audits FAQ
What is a compressed air system audit?
An audit evaluates how compressed air is produced, treated, distributed, and used. It helps identify performance problems and opportunities to reduce unnecessary energy use or improve reliability based on the facility's actual operating conditions.
Why should a facility consider a compressed air audit?
An audit can clarify the causes of unstable pressure, high operating costs, or insufficient capacity. It provides a basis for prioritizing improvements and evaluating whether proposed equipment purchases address the real system need.
What parts of the system should an audit examine?
A system review considers supply, distribution, and demand, including compressors, treatment equipment, storage, piping, controls, and end uses. Confirm the scope and measurements included in the proposed audit for your facility.
What is the difference between an audit and a leak survey?
A leak survey focuses on locating escaping air. A comprehensive audit evaluates broader system behavior, including pressure, demand, compressor loading, controls, and distribution losses. Leak identification may form part of that larger investigation.
Can an audit explain why pressure drops during production?
It can help distinguish insufficient supply from local restrictions, treatment losses, or short-duration demand peaks. Measurements taken under representative production conditions are useful for identifying where and when pressure changes occur.
Can an audit help determine whether I need another compressor?
Yes. Reviewing actual demand and system losses can show whether additional capacity is necessary or whether existing capacity can be used more effectively. The conclusion should be supported by measured operating data.
What measurements are useful during an air audit?
Useful data may include airflow, pressure, electrical power, compressor operating states, and production schedules. The necessary measurements depend on the investigation, so confirm the proposed instrumentation and monitoring period before work begins.
Why should measurements cover different shifts or operating periods?
Air demand can change with production schedules, equipment use, and idle time. Monitoring representative conditions helps avoid sizing improvements around a brief snapshot that misses peak loads or unnecessary off-shift consumption.
Can an audit help reduce energy costs?
An audit can identify opportunities involving leaks, pressure settings, controls, inappropriate air uses, and distribution restrictions. Actual savings depend on the findings, implementation costs, operating hours, and verification after the changes.
How are potential savings and payback evaluated?
Compare the measured baseline with the expected performance after a proposed change, using actual operating hours and energy rates. Include project costs and ongoing expenses, and clearly distinguish estimates from verified results.
Does lowering system pressure always solve energy problems?
Lower pressure may reduce energy use, but the system must still meet equipment requirements under peak demand. Investigate distribution losses and control behavior before changing settings that could affect production quality or reliability.
Can an audit evaluate air storage and demand peaks?
Yes, when included in the scope. Comparing short-duration demand with pressure and compressor response can help determine whether appropriately placed storage or control changes would improve the system's response.
Will the audit require a production shutdown?
Many useful measurements relate to normal production, but instrument installation or specific inspections may require planned access or isolation. Industrial Air Services can discuss the proposed activities and scheduling requirements for your facility.
What should I provide before an audit?
Gather compressor and dryer information, operating schedules, energy rates, piping drawings, known pressure problems, and production expansion plans. Existing trend data and maintenance records can help focus the investigation on recurring concerns.
What should happen after an audit?
Review the findings, prioritize practical improvements, and assign responsibility for implementation. Confirm expected costs and benefits, then measure performance afterward to determine whether the changes delivered the intended result.
How do I schedule a compressed air audit in Tennessee?
Contact Industrial Air Services at (615) 641-3100 with your facility location, equipment information, operating schedule, and main concerns. The team can discuss an audit scope suited to your system and improvement goals.