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July 9, 2018 By Tom Sherman

Compressed Air Audits and What’s Involved

A compressed air system audit can show the actual cost of compressed air and identify simple ways to cut energy costs. Compressed air is a facility’s most expensive utility. By comparison, if a simple machine used 5 HP for 10 minutes to lift an object and the power could be provided by either electricity, natural gas or compressed air, the compressed air would be roughly 8 times more expensive than electricity and about 22 times more expensive than natural gas, to do the same work.

Compressed air system users should consider using an independent auditor to examine their compressed air system.  Several firms exist that specialize in compressed air system audits. Audits are also performed by electric utilities, equipment distributors and manufacturers, energy service companies, and engineering firms.  An informed consumer should be aware that the quality and comprehensiveness of audits can vary.  Independent auditors should provide recommendations which are brand and systems-neutral.

A comprehensive compressed air system audit should include the following:

  1. Level of air treatment – Since increasing air treatment also increases energy usage, it is important to ensure that air treatment is optimal for the application.
  2. Air leaks – Only 5% of air leaks can be heard by the human ear. It takes special instrumentation to detect all air leaks in a system. An auditor is able to detect all leaks and tag them. Maintenance can then focus on repairing the largest leaks first by referring to the CFM level shown on the tag.
  3. Pressure levels – An auditor will determine the lowest pressure level required to satisfy all downstream requirements. In some cases, dedicated storage or deferential reduction may be needed.
  4. Controls – The existing control system is evaluated to determine if it is correct for the system demand profile. Gains in system performance are considered using alternative control strategies.
  5. Heat Recovery – An auditor will identify a  potential use for waste heat recovery if not already in use.
  6. Air Distribution System – The auditor will examine the overall layout and size of the piping, including the placement and size of any receiver tanks. Pressure drops and condensate removal are also evaluated with recommendations. Large load “clusters” are also mapped.
  7. Load Profile – The compressed air load profile is determined based on CFM changes over time. A varying load profile may suggest a different control strategy while a short period of very high demand my suggest an alternative storage option.
  8. Compressor Motor – The motor should be checked as part of an audit. Abnormal thermal and vibration patterns may suggest imminent motor failure or shortened life.
  9. Equipment Review – Filters, dryer, aftercooler, automatic drains, tanks, solenoid valves, etc. are all checked for proper sizing and function during an audit.

Compressed air audits can substantially cut energy costs as well as improve system operation. If you haven’t had one in the past 3-years, it only makes sense to schedule one.

Filed Under: Blog Tagged With: compressed air, compressed air assessment, compressed air audit, energy audit

What Our Clients Are Saying

“It has been a pleasure working with Laura and Tom Sherman and Sustainable Energy Services over the past three years on our energy procurement.  They have saved our company many thousands of dollars on our energy spend year over year and I have appreciated the regular and timely insights on our electric and gas accounts. Tom completed an energy audit of our facility and uncovered many opportunities to reduce energy consumption.  He also made us aware of a tariff opportunity that will save us … Read more
Wayne Pedlar, Chromaflo Technologies
Tom did a complete audit of our facility and then mapped out a strategy that we have followed for the last 4 years.  To date we have saved 47%.  We were so delighted with our results, we asked him to help us with our 3 other plants.  Tom is very professional and a joy to work with.  I would not hesitate to recommend Tom and his firm if you are looking for a high integrity expert who gets results.  
Jeff Weekley, CFO, Mantua Mfg. Co.
Tom did a complete facility energy audit, which got us started on reducing our energy consumption. From his report, we were able to improve our lighting, replaced our old boilers with infrared heat and tackled our compressed air system.  Since 2010, these and other projects help us achieve a 41% reduction in natural gas usage and an 18% reduction in our electricity usage.  Tom has always been available for special projects or advice whenever we needed it.   It has been a pleasure to work with… Read more
Chris Schwartz, President, G&S Metal
Sustainable Energy Services performed a complete facility energy audit, showing us how we could save 30+% on our energy usage.  From the final report it was clear we needed to move first on upgrading our lighting. Looking at the math, it was a no-brainer. Based on the unbiased financial analysis provided in the report, we saw a clear way to upgrade to all LED lighting with less than a 2 year payback so we implemented it.  SES also helped us with utility rebates, get competitive bids and secure… Read more
Terry Schordock, Property & Systems Director, Bay Presbyterian Church
In today’s retail environment, margins tend to be diminishing all over the place; retailers need to get creative in order to stop the bleeding, find ways to increase sales, and move the needle on the trend to stay alive and relevant.  One expense area that I noticed was significant was our electric bill, and I decided to delve into how to potentially reduce it.  After researching solar alternatives, it was suggested to me that I first conduct an overall energy audit to identify where and how o… Read more
Charlie Bassett, CEO, Bassett's IGA

News and Updates

SES is proud to announce that our CEO, Laura Sherman, graduated Goldman Sachs 10,000 Small Businesses program.

Laura was among 26 small-business leaders from across Northeast Ohio an beyond who completed the … [Read More...]

We are excited to be invited speakers at the AEE East and West Energy Conferences, which are combined this year and will be virtual. Tom will present on Electric motors and VFDs.

… [Read More...]

Tom is honored to be selected as a speaker at the AEE 2020 World Energy Conference, December 1-4, 2020. His topic this year is Compressed Air System Best Practices: How to Conduct an Audit for Optimal Performance.

… [Read More...]

Tom is honored again to be selected as a speaker at the 2020 AEE East Energy Conference in Cincinnati, OH, April 21 & 22

The 2020 AEE East Energy Conference will be held at the Duke Energy Convention Center, Cincinnati, … [Read More...]

Tom will be presenting Motors & VFDs at OTCOs 58th Annual Water Workshop in Columbus March 10 and 11, 2020

Tom will be presenting on Motors and VFDs: How They Work and When They Don't at the Operator … [Read More...]

Tom is presenting “Compressed Air Auditing: Going Deeper for Better Results,” at the AEE World Energy Conference

Compressed air audits often miss areas that would further reduce energy consumption, more accurately … [Read More...]

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