Fluid-Aire’s 20-Point System Assessment
1- Review Overall System Layout
Get a general idea of the system layout including air compressor(s), air dryer(s), filtration, oil/water separators, and piping.
2- Review System Equipment List
Record compressed air equipment in use in the system. Manufacturer, model number, serial number recorded for all units. we will note the CFM/kW/HP as well as the total operating hours, for the compressors and the CFM for any dryers and oil/water separators. Also note inline filtration units and filter types.
3- Check for Efficient Drain Operation
Do you have zero loss drain valves? If not, we can work with your energy provider for incentives on installing new ones.
4- Check for Optimized System Pressure
Is 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.
5- Check for Point-of-Use Regulation
Check line pressure regulators are functioning properly under pressure at smaller machines. check to make sure PSI falls within tolerances.
6- Confirm Proper Dryer & In-Line Filtration Function
Dryers can only be expected to operate properly when they are correctly sized and installed. All dryers have ratings based on a specific set of conditions, as these conditions are exceeded the capacity of the dryer will change, and in some cases fairly dramatically.
7- Check for Moisture & Proper Air Quality
Monitor Dew Point at multiple usage points to verify, making sure it falls into the design proper range of your dryer, check for water in the lines, check filtration and dryer.
8- Assess Need for Point of Use Drying
Is point-of-use drying in place? If not, could your system benefit from this?
9- Detect Presence of Oil/Water Condensate in Compressor Area
Is an oil/water separator in place? Could your system benefit from one. How is oil/water being collected and disposed of? Is condensate pooling near the compressor?
10- Identify Improper/Wasteful Uses of Compressed Air
- Clean up – Use a broom on floors, brushes on benches, brushes on clothes
- Drying, Process Cooling – Use low pressure blowers or fans
- Sparging – Use low pressure blowers or electric mixers
- Vacuum Generation (Venturi) – Use electric vacuum pump
- Personnel cooling – Use fans
- Air motor driven mixers – Use electric mixer
- Idle Equipment – Turn off the air valve supplying the equipment
- Abandoned Equipment – Completely disconnect from air system
- Leakage to Atmosphere – Repair/replace bad hoses, couplers, solenoid valves, pipe joints, etc.
11- Calculate System Leak Rate
Let’s take a walk around your plant, following your compressed air lines. Can we hear any leaks? We can also use ultrasonic leak detection equipment if necessary. Are these leaks causing your system to be set at a higher pressure than necessary, resulting in additional wasted energy?
12- Check for Short-Cycling & Adequate Storage
Are your compressors turning off and on again repeatedly, or loading 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?and unloading more often than usual? If so, this could cause premature motor or inlet valve failure.
13- Check for Proper Mode of Operation on Controller
What mode are your air compressors operating in; start/stop, load/unload, or modulation? Is the mode selected best for your operating conditions?
14- Assess the Need for Variable Speed Drive
A VSD air compressor is able to adjust the amount of power used in response to CFM demand in real time. This provides significant advantages, especially for companies whose compressed air needs vary over the course of a shift, day or season. Energy Incentives may be available to you toward the purchase of a VSD compressor. Would this technology be a good fit for your facility?
15- Note Ambient Condition & Heat Ventilation
What are the ambient conditions for your compressed air equipment? Is your environment clean or dirty? This has an impact on how often recommended maintenance should be completed on your compressed air equipment. Check for the key factors that impact the location of your air compressor.
16- Check for Proper Operating Temperature
Is your compressed air equipment in the optimal ambient temperature range (between 50° and 85° F)?
17- Assess Loaded vs Unloaded Hours for Oversized Compressor
Monitor history of load/unload cycles. Check run cycle timing and data logging if necessary.
18- Check for Proper Safety Valve for Total HP (including back-ups)
Do your receiver tanks have properly sized safety valves installed in order to avoid dangerous over-pressurization situations?
19- Determine Energy Incentives Available
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- Identify Any Special Uses or Demands?
Check duty cycles of air compressor, perform a leak survey (if warranted), check point of use and regulator for mis-sized hoses, check for any special industry related needs.
We provide industrial air compressors, air dryers (refrigerated air dryers, desiccant air dryers), compressed air systems, and parts nationwide. Contact us if you need help selecting the right compressed air equipment for your application.