System Assessments

20 Point System Assessment Checklist

 

  1. Overall System Layout – Get a general idea of the system layout including compressor(s), dryer(s), filtration, oil/water separators, and piping.
  2. Record Your Compressor Equipment Models – Record compressed air equipment models
    • Air Compressor #1 Model
      • CFM/KW/HP
    • Air Compressor #2 Model (if applicable)
      • CFM/KW/HP
    • Air Dryer #1 Model (if applicable)
      • CFM
    • Air Dryer #2 Model (if applicable)
      • CFM
    • Oil/Water Separator Model (if applicable)
      • CFM
  3. Overall System MaintenanceHow often is your compressed air equipment currently being serviced and when was the last time it was completed? Who is doing your maintenance currently? Do the machines look up-to-par in comparison to what they should look like on their current maintenance routine?
  4. Auto Timer Drains Properly SetDoes your compressed air system have auto drains? If so, are they properly set and being regularly cleaned?
  5. Zero Loss Drains?Do you have zero loss drain valves? If not, we can work with your energy provider for incentives on installing new ones.
  6. Excessive System PressureIs your air compressor equipment producing more pressure than what the highest PSI requirement is within your production processes? As a rule of thumb, every 2 PSI of over-pressurization costs you 1% in energy.
  7. System Pressure ReducerDoes your compressed air system include a pressure regulator / flow controller? If not, would it benefit from one?
  8. Dryer Dew Point – Is your dryer performing correctly? Is your air dry at all points of use?
  9. Point Of Use Drying – Is point-of-use drying in place? If not, could your system benefit from this?
  10. Improper uses of compressed air? Read our blog on inappropriate uses of compressed air.
  11. LeaksLet’s take a walk around your plant, following your compressed air lines. Can we hear any leaks? We can also use electronic leak detection technology if necessary. Are these leaks causing your system to be set at a higher pressure than necessary, resulting in additional wasted energy?
  12. Short Cycling?Are your compressors turning off and on again repeatedly, or loading and unloading more often than usual? If so, this could cause premature motor or inlet valve failure.
  13. Mode of OperationWhat mode are your air compressors operating in; start/stop, load/unload, or modulation? Is the mode selected best for your operating conditions?
  14. Proper Tank Storage – Do you have a wet tank and a dry tank? If not, do we need to add more storage? Based off of the rule stating that, 3 gallons of compressed air storage per 1 CFM of system output capacity, is your storage adequate?
  15. Variable Speed Drive? – Do you currently have a variable speed drive air compressor? If not, would this technology be a good fit for your facility?
  16. Cycling Dryer? – Do you currently have a cycling or non-cycling dryer? If not, would this technology be a good fit for your facility?
  17. Ambient Condition Analysis – What is the ambient room conditions of your compressed air equipment? Is your compressed air equipment in the optimal ambient temperature range (between 50 and 85 degrees Fahrenheit)? Is your environment clean or dirty? This has an impact on how often recommended maintenance should be completed on your compressed air equipment.
  18. Safety Valve Installed?Do your receiver tanks have properly sized safety valves installed in order to avoid dangerous over-pressurization situations?
  19. Energy Provider Incentives? – Many energy providers give incentives on zero loss drains, variable speed drive compressed air equipment, and leak repair. We will work with your provider to see if any incentives are available for your company.
  20. Recommendations – We will advise you on any recommendations we have for your system, based upon our findings and engineering experience. Also at this point, we will determine whether data-logging is necessary or not.