Compressed Air Audits

Compressed air, commonly referred to as the 4th utility, is an expensive and inefficient part of the production process. For every 8 horsepower of electricity consumed, only 1 horsepower of work is produced. According to the U.S. Department of Energy, compressed air represents about 10% of the electricity use in the United States. Although compressed air is inefficient, it is vital across industries and remains as the safest and best way to store and use energy. Much can be done to control and reduce compressed air wastage. Creating an efficient compressed air system should be a top priority. In our experience, 15-35% can be saved by performing an air compressor audit.

Pattons certified audit team is experienced in performing assessments on compressed air systems of all sizes and types. We have auditors on staff with the following certifications:

  1. Certified U.S. Department of Energy AIRMaster+ Specialist
  2. CAGI Certified Compressed Air System Specialist

All of our audits are performed according to the principles and guidelines put in place by the Compressed Air Challenge and the U.S. Department of Energy.

Our goal for performing compressed air audits is to provide accurate results to save our clients thousands of dollars a year as well as to assist plant personnel with critical information for the decisions pertaining to future growth and efficiency. To provide a full scope of this information, we recommend the following process:

  1. Baseline Audit – This provides a baseline to measure the actual performance and efficiency improvement measures implemented throughout the process

  2. Demand Side Audit – A qualified auditor will spend time in the facility, evaluating your process and compressed air usage to determine if there are any alternate methods which will perform equally with less or no consumption of compressed air. We will also look for poor practices and means of reducing pressure drops.

  3. Compressed Air Leak Study – Using ultrasonic leak detection, our auditor and service team will find and tag compressed air leaks in your facility. Leaks will be categorized by intensity and prioritized. There may be energy provider rebates for performing this study which will help or fully cover the cost of this service.

  4. Supply Side Audit – Once the demand side recommendations have been completed, and the leaks have been repaired, we will perform a Supply Side Air Audit similar to what we did in Step 1. Our focus will change slightly as we will tune in on the compressor room and how efficiently you are generating compressed air based on your reduced demand. Product neutral recommendations will be prepared with return on investment on each recommendation.

  5. Implement Recommendations – Changes are made to supply side system by Pattons or your chosen service provider.

  6. Verification Audit – This is a very simple audit showing the new lower energy cost, flows, pressures and any other relevant data to verify the recommendations as long as the solutions implemented follow the guidelines proposed. This data is also collected for energy providers in order to issue the customer incentive rebates, if applicable.

Contact us to request more information on compressed air audits or to schedule a visit.

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