Compressed Air and Vacuum Audits
Although each system is unique and requires emphasis in certain areas, the basic Audit Analysis includes:
- Determining the actual capability and condition of the supply equipment including the compressors, dryers, filters, cooling systems, etc. Their actual efficiency compared to design efficiency allows us to determine the long term viability of all supply equipment.
- Measuring the storage capabilities of the system and its relationship to the changes in air demand that occur in the system. Determining the demand event sizes and comparing them to the relationship of supply power and storage is the key to stabilizing the system pressure and often provides major opportunities for efficiency improvement.
- Evaluating the pneumatic applications in the system including waste, such as leaks, artificial demand, and inefficient applications. Eliminating the waste in the system with engineered alternatives is another area for operating cost reduction. Preliminary leak audits are included in all audits to provide an accurate assessment of the practical opportunity to reduce air demand through repairs. Complete leak audits are available at reduced rates as part of a system audit.
- Analyzing and providing solutions to correct applications that are not performing acceptably. Correcting applications which require excessive pressure enhances productivity and provides the flexibility required to operate the supply system at peak efficiency.
- Creating an existing process flow diagram which depicts the general arrangement of the system and the supply power and demand volume in all operating conditions. This single page document allows plant personnel to grasp even the most complex system so that a strategy for managing it effectively can be attained. Creating a proposed arrangement process flow diagram which allows us to analyze the ability of the reconfigured system to meet all demand conditions.
- Determining the total operating costs of the system including energy, maintenance, labor, cooling water, etc. Calculating the efficiency of the system in terms of costs vs. air demand supported will allow us to compare your costs and efficiency to industry norms and optimal arrangements. Projecting the operating costs for the proposed arrangement allows us to calculate a return on investment for the recommended improvements to the system.
- Developing a prioritized action plan with capital costs and estimated installation costs for the proposed modifications to the system. This action plan becomes a guide for implementing the recommendations and helps insure that the desired results will be achieved.
- Providing a complete audit report including existing and proposed process flow diagrams and pressure logger graphs which identify any restrictions in piping. Any necessary piping modifications will be clearly defined in the action plan.
iZ Systems has designed and installed hundreds of compressed air and industrial automation systems which gives us the practical experience of actually making a system run as intended. This experience has strongly influenced our audit and design methods which tend to be very practical and maximize the ROI and provide long term retention of energy savings for the client.