Air audits for Compressed Air Management

Air audits evaluate the efficiency of use of compressed air in an operation. Air audits can identify energy savings from better compressor selection, improved line design, arresting leaks, and optimizing usage. Compressor manufacturers and independent air audit experts are capable of conducting air audits. While methods vary, an air audit expert will use flow meters, power analysers, water flow meters, digital pressure gauges, anemometers, infrared thermometers and condition monitoring equipment to evaluate an operation’s air usage.

Following the analysis, the team submits a report with a summary of potential savings, along with recommended changes and associated costs. Typically, they will spend sufficient time to gain a representative understanding of varying demand conditions.  Following the analysis, they will issue a report with a summary of the potential savings along with the recommended changes and associated costs to realize the savings. Some common problems the team sees are incorrect compressor size, inadequate air distribution system, incorrect positioning of downstream accessories and air receivers, and poor regulation of pressure.

 

While compressor selection, line design and line monitoring have been discussed, air auditors will also review the nature of use. For instance, operators in compressed air intensive operations such as textiles will often use a higher than required pressure to operate their machinery.

An air auditor might test these machines at lower pressures, and if there is no disruption, the mill operators can continue to operate at a lower pressure, thereby enjoying energy savings. In addition, an air auditor may also recommend against using compressors for energy wasting applications such as cleaning.

ELGi has been conducting air audits for not only companies that use ELGi products but also those using other compressor brands. Since 2011 when ELGi started conducting air audits, it has completed over 250 air audits and proposed savings worth Rs. 62.51 crores. For the textile industry alone, ELGi has conducted around 135 air audits.

The following are the summary of air audit reports that showcase the savings accrued out of air audits conducted by ELGi in leading textile mills.