Free Compressed Air System Assessment
Reduce waste, identify savings opportunities, and optimize compressed air system performance with a free Compressed Air System Audit from Fluid-Aire Dynamics. Our qualified compressed air systems experts will conduct a comprehensive 20-point compressed air assessment to document equipment performance, air demands, maintenance requirements, and optimization recommendations.
When do you need a compressed air system assessment vs. a complete system audit?
A compressed air system assessment should be done periodically to identify inefficiencies and optimize system performance. A complete audit is necessary when experiencing persistent system issues, considering major upgrades, or after significant changes to production demands. Both ensure optimal energy usage and system reliability.
Brands We Serve
With over 30 factory-trained service technicians, we have deep experience in air compressor maintenance, service, and repair for businesses and commercial applications. We service almost any brand of commercial air compressor (e.g., rotary screw or hydrovane-style air compressor), including: Atlas Copco, Champion, Chicago Pneumatic, Curtis Toledo, Elgi, Gardner-Denver, Hydrovane, Ingersoll-Rand, Kaeser, Kaishan, Mattei, Pneu Tech, Quincy, Saylor Beall, Sullair, Sullivan Palatek, and many, many others.
How It Works
Our factory-trained compressed air experts conduct a thorough 20-point assessment of critical components of your compressed air system to identify opportunities for cost savings and ways to save energy. We use data logging equipment, such as amp meters and pressure gauges, to analyze supply side performance of your air compressor and system. Then we give you a report that documents your air demand, system performance, and optimization opportunities.
- Review Overall System Layout
- Review System Equipment List
- Check for Efficient Drain Operation
- Check for Optimized System Pressure
- Check for Point-of-Use Regulation
- Confirm Proper Dryer & In-Line Filtration Function
- Check for Moisture & Proper Air Quality
- Assess Need for Point-of-Use Drying
- Detect Presence of Oil/Water Condensate in Compressor Area
- Identify Improper/Wasteful Uses of Compressed Air
- Calculate System Leak Rate
- Check for Short-Cycling & Adequate Storage
- Check for Proper Mode of Operation on Controller
- Assess the Need for Variable Speed Drive
- Note Ambient Condition & Heat Ventilation
- Check for Proper Operating Temperature
- Assess Loaded vs Unloaded Hours for Oversized Compressor
- Check for Proper Safety Valve for Total HP (including back-ups)
- Determine Energy Incentives Available
- Identify Any Special Uses or Demands
Maintenance Tips and Benefits
Compressed air system maintenance is essential to ensure the proper operation and overall efficiency of the air compressor and system components. Your compressed air system assessment can help optimize preventative maintenance intervals. Always follow manufacturer's recommendations and complete all regular maintenance tasks in a timely manner to prevent costly breakdowns, unplanned downtime and excess energy consumption. A typical air compressor maintenance checklist might include:
- Daily maintenance tasks: Check oil level (add if necessary), inspect system for oil leaks, drain water from tanks and dryers, monitor pressure levels, listen for unusual noise
- Weekly maintenance tasks: Check air intake filter (change or clean if necessary), clean exposed surfaces (especially heat exchanger/cooling systems), check belts and fastenings
- Monthly maintenance tasks: Check differential pressure across inline filters and change if necessary, inspect hoses and connectors for air leaks, verify pressure relief valve and cooling systems are working, inspect oil and oil filter (change oil and filter if necessary); inspect air/oil separator; check power connections and control systems
- Annual maintenance tasks: Change oil and oil filter, service motor and grease motor bearings, complete full air compressor maintenance checklist
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What are the benefits of a compressed air system audit?
A compressed air system audit can help you save money and energy, optimize the performance of your system, make informed decisions about upgrades or reconfigurations, and avoid unnecessary downtime. Your factory-trained technician will evaluate all aspects of system performance, document patterns in air demand for your facility, and identify any emerging problems or issues that need attention. Then, they will recommend any improvements that can be made to improve reliability or efficiency or better meet current or future air demand requirements. A compressed air audit will help you: • Understand your current air demand patterns and where the air is being wasted through leaks or misuse. •Check compressed air quality, including moisture levels, oil carryover, and contaminants. • Determine the optimum PSI for your compressed air system and whether your air compressor and dryers are properly sized for your air demand. • Check the functioning of compressors, dryers, drains, and other compressed air system components to make sure everything is operating correctly. • Find opportunities to reduce air or energy waste and optimize system settings for maximum efficiency. • Identify emerging problems (such as oil leaks, blockages, etc.) that could lead to unexpected downtime, poor system performance or air quality problems. • Make decisions for system upgrades and improvements.
How long does a full compressed air system assessment take?
Your sales engineer will complete the system inspection and evaluation on the day of your appointment. For a smaller compressed air system, this may be completed in an hour; a larger, more complex system may require a couple of hours onsite. If your audit includes data logging, we will leave the data logging equipment on your system for one to two weeks after your initial appointment. After we retrieve the equipment, you will have your full report in a couple of days.
Who will conduct the compressed air system assessment?
All of our compressed air system assessments are completed by factory-trained, qualified professionals with in-depth training and experience in compressed air system design. They will not only complete the audit, but also explain the findings to you so that you understand exactly what your data are telling you. Our people are highly trained so you can count on their insights and recommendations as you make decisions about your compressed air system.
How do you test compressed air quality?
Compressed air testing is performed using specialized equipment to measure commonly found contaminants (such as particulate matter, moisture, and oil carryover), ensuring it meets industry standards for compressed air quality. Typically, this will involve taking a sample of compressed air and sending it to an accredited lab for testing.
How do you test for leaks in compressed air systems?
Compressed air leaks are typically detected using a specialized device called an ultrasonic leak detector. Finding and fixing air leaks will help your system maintain pressure and reduce energy costs for your compressed air system.
What are the 4 components of a compressed air system?
What are the safety requirements for compressed air systems?
Safety requirements for compressed air systems are essential to protect both the equipment and the personnel working around them. Safety requirements include:
- Make sure the system is installed correctly according to manufacturers specifications
- Perform regular compressed air system maintenance, inspection and verification using a maintenance checklist tailored to your compressor type and usage levels
- Ensure maximum pressure does not exceed equipment ratings
- Install pressure relief valves and make sure they are working
- Use ASME certified receiver tanks and complete regular inspections
- Follow all manufacturer's recommended guidelines for maintaining your air compressor and make sure all users have appropriate training
How do you test a compressed air system?
A compressed air system assessment may include a variety of tests to collect data using a pressure gauge tool, amp meter and other deviled to check pressure, flow rate, overall leak rate, and other aspects of system performance. A system evaluation will also include visual inspection of your system to evaluate the system layout, compressor installation, and other variables that will impact system performance.