Air Compressor Audit Services
Save energy, reduce costs, and increase efficiency with a Compressed Air System Audit. If it's time to upgrade, replace or improve your industrial or commercial compressed air system, start here. If you don't know if you need to upgrade, keep reading; it may be beneficial to have an air compressor efficiency study completed. Like the old saying goes, YOU CAN’T MANAGE WHAT YOU DON’T MEASURE!
Energy Efficiency Audit for Your Equipment From Trusted Air Experts
Fluid-Aire Dynamics is the leading compressed air audit company in Chicago, Milwaukee, Minneapolis, Detroit, Pennsylvania and San Antonio. Our industry experts will perform a detailed Compressed Air System Efficiency Audit to locate compressed air leaks, determine where air is being wasted, and identify opportunities for energy improvement throughout your system.
How We Can Help
Our air experts at Fluid-Aire Dynamics will identify system improvements that could shave thousands off your compressed air energy bills. We use a proven and repeatable compressed air audit procedure based on data from your current operations. Your compressed air audit report will outline clear and understandable recommendations for improving the reliability and efficiency of your system. We'll help you:
- Conduct a data logging study of your existing system and set performance benchmarks
- Make recommendations for any energy-saving opportunities, including correctly-sized air compressor(s) and the optimal blend of fixed- and variable speed drive (VSD) compressors
- Evaluate and improve your compressed air distribution piping system
- Assess compressor room setup and controls and determine if upgrades are needed
Air leak audit
The typical compressed air system loses between 20-35% of compressed air to leaks, although more than 50% is not uncommon. These leaks may be costing your facility hundreds or thousands of dollars in excess energy costs. An air leak audit can help you find these hidden leaks so you can cut the waste and save precious air, energy and money. And energy incentives from your power company may pay for the entire cost of your air audit and leak repair.
Compressed Air System Efficiency Audit
The compressed air system efficiency audit is the place to start before making any changes, upgrades or improvements to your air system. We use data logging and other air audit procedures to analyze system performance. When your audit has been completed, you will clearly understand the factors that impact your system performance.
AMPERAGE DATA LOGGING
Amperage data logging is a simple and non-invasive data logging method. By attaching an amperage recorder on the compressor controls, we can determine your peak and average air demand, the duty cycle of your compressor, energy consumption, and other key aspects of system performance.
CFM DATA LOGGING
Flow meters are used to measure how much air the compressor is producing in cubic feet per minute (CFM), which provides insights into compressor performance, demand patterns, and whether compressor capacity meets demand. Flow metering can also be used to help estimate leak rates for the system.
PSI DATA LOGGING
Pressure loggers are used to measure the pressure produced by the compressor (in pounds per square inch, or PSI). By attaching pressure meters at various points in the compressed air distribution system, we can determine the PSI at each point of use and where you are experiencing pressure drop across the system.
Our Compressed Air Audit Process
The Fluid-Aire Dynamics Compressed Air System Efficiency Audit is a multi-step process that uses data collection and expert analysis to help you understand your compressed air system and identify areas for improvement. We go through a compressed air audit checklist to gather information about every aspect of system performance. At the end, you'll receive a detailed compressed air audit report with actionable information you can use to make decisions about system upgrades, improvements and optimization.
A data logger is clipped to the incoming power of your compressor. The data logger measures pressure, amperage and voltage for your air compressor.
The data logger is left in place for one to two weeks to collect data. This allows us to understand patterns and cycles in air usage over the course of normal shifts, days and weeks. At the end of the data collection period, the data logger is retrieved and returned to our service facility for analysis.
Our compressed air system experts use the data to analyze the performance of your system and produce a detailed compressed air audit report. The analysis will help you to understand important aspects of system performance, such as air compressor duty cycles, peak demand times and rates, and whether you are running out of air at key times.
Your Sales Engineer will review your compressed air audit report with you and your team. We will make recommendations and help you implement a plan that solves for the efficiency issues that are discovered.
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Why do our clients think that we are the best Compressed Air System Audit Service?
Do you know if your compressed air system is costing you too much money in energy bills? Compressed air is the fourth and most costly utility in manufacturing facilities. If your system is inefficient, this expense will be higher than it needs to be. A compressed air efficiency audit will help you save money, reduce maintenance, improve your energy footprint and guarantee consistent, reliable performance for your compressed air system.
We are the compressed air experts in Chicago, Milwaukee, Minneapolis, Detroit, Philadelphia and San Antonio. When you work with us for your compressed air energy efficiency audit, you can count on:
- Highly trained and qualified technicians who know how to collect and interpret the data from your compressed air system.
- Easy-to-understand, actionable information presented through a detailed Compressed Air Audit Report.
- Help in making decisions and implementing strategies for optimizing your compressed air system, from right-sizing your compressor to finding and fixing leaks.
- Assistance in qualifying for energy incentives that could cover part or even all of your audit and system upgrade costs. We'll even fill out the paperwork for you!
- A compressed air partner who will stand behind our work and be there for you over the long haul to keep your system running at optimal performance levels.
The variable speed drive air compressor helps us because we don’t have any regulators on our equipment in the building. When a technician is using an impact that’s rated for 90 PSI, I turn the compressor down to 90; when we’re using the bead blaster, I walk up to the compressor and bump it up to 105. The bead blaster only puts our compressor under about a 30% load. It’s so quiet—the bead blaster is 100x louder than the air compressor is! The VSD compressor saves me time and money.
Ron S. - Deutz Corporation
The salesman was able to answer EVERY question I asked. The delivery was prompt and the set up fulfilled my needs. Your service tech was excellent in his knowledge of the product, cleaned up after the service and gave us a few tips on how to care for the unit to prolong its life.
Ken P. - Pullman Sugar
I would recommend Fluid-Aire to anybody. Your guys stand up for the work you do and the equipment you put in our facilities, and you’re always very easy to work with.
Felix M. - Plant Manager, Bolke-Miller Company
Fluid-Aire isn’t tied to any one compressor brand. They will give you the best overall solution for your operations. They aren’t going to try to upsell you on something that you don’t need. With a lot of companies, once you buy a compressor, you never see them again. I like that Fluid-Aire is local and family owned. I know if I ever have a problem, they are going to be here for me. Fluid-Aire Dynamics is receptive, proactive, and they are a family-owned business, like us. I appreciate the care and personal attention they give us.
Ryan W. - VP of Operations, Wiegel Tool Works
Elk Grove Village, Illinois
How often should an air compressor be inspected?
We recommend that your air compressor and compressed air system components be inspected at least annually. However, larger data logging studies to evaluate total air usage, peak demand and energy use may be performed less frequently.
What can I expect to pay for a compressed air audit and what are the typical outcomes?
Engineering firms may charge anywhere from a few hundred dollars to up to $10,000 depending on the types of assessments performed and the complexity of the compressed air system. The outcomes of a compressed air system audit are well worth the costs, however. And in some cases, your energy company may pick up the bill.
The audit will help you identify opportunities for energy savings and optimize your system for current and future demand. You should expect:
- Detailed System Assessment: The audit will provide a comprehensive understanding of the current state of your compressed air system, including inefficiencies and potential problems.
- Recommendations for Improvement: The audit should identify opportunities for improvement. This could include fixing leaks, adjusting pressure settings, replacing inefficient components, or even installing a new, more efficient compressor.
- Energy Savings: Implementing the recommendations from the audit should result in energy savings. The amount will depend on the current state of your system, but it's not uncommon to achieve energy savings of 20-50%.
- Reduced Maintenance and Downtime: Improvements identified in the audit can also lead to lower maintenance costs and less downtime due to equipment failures.
- Baseline for Future Improvements: The audit establishes a baseline of system performance against which future improvements can be measured.
How long does it take to audit the air compressor system?
A typical data logging study will take about two to three weeks and will not require any downtime on your part. We simply hook the data logging devices to your system, come back and get them one to two weeks later, and then run your report. The full report and audit results will take about one week after the data has been retrieved.