Keeping an eye on compressed air systems

With no short-term solution in sight to mitigate soaring energy prices it is essential for plant managers to take steps to ensure that compressed air systems are operating to their full potential. That means identifying and eliminating air leaks, optimising performance, and reducing energy consumption to drive down costs.

It is a fact that compressed air systems account for 10% of all electricity used in global industry, so with the current high electricity prices there is more reason than ever to generate compressed air more efficiently. Another fact is that on average 25% of compressed air is wasted through leaks – even a 3mm leak would now cost operators several thousand pounds per year more than it would have cost last year.

With these facts in mind, there is an increased need to measure performance and drive out any inefficiencies, no matter whether the aim is to improve an existing system or to make informed decisions on new compressed air equipment purchases. 

Optimisation of compressed air systems impacts performance and efficiency significantly. It lowers fuel bills and reduces carbon footprints. The simplest and most effective means of achieving these optimisation goals is to carry out a health check and an energy audit – assessments can be performed quickly and accurately on-site, usually with zero disruption to production operations.

One important aspect of any check is to identify and eliminate leaks caused by issues such as corrosion, poor pipe connections, or bad seals - problems which can add up to a significant amount of wasted energy over time.

There is a system of health checks and energy audits for a compressed air installation. After initial visual assessment, energy potential calculations (EPC) can also be carried out. These focus on the power usage of the compressors, load v. unload hours, and average leak assessment. 

Next comes energy assessment and recommendations. Data logging equipment fitted to each compressor can record and map the energy consumed over a full week period and shows the actual running hours, calculated air usage and quality of the compressed air including dewpoint. From this data, it is possible to calculate a realistic energy savings potential, make simulations, and provide recommendations to achieve optimal energy efficiency. 

Finally, a full audit to ISO 11011:2013 standard provides a premium assessment of various parameters throughout the wider system, from compressor room to production processes. Included in the audit are reporting and discussions of the most suitable methods to reduce energy costs and CO2 emissions. 

A typical audit system will identify tangible measures that can result in 25-30% energy savings while offering analysis and actionable insights for energy efficiency improvements. Today, audit software can simulate various configurations of a compressed air installation and enables the audit operators to provide realistic projections on potential energy savings.