Fluid-Aire Dynamics Service

Compressed Air System Auditing

Service Areas: Illinois, Michigan, Minnesota, and Wisconsin

Fluid-Aire Dynamics

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.

Compressed Air System Auditing Image

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. So how can you tell if your system is as efficient as possible?

Fluid-Aire Dynamics offers free data logging that shows your usage of air and how it varies throughout your working hours. This helps you to determine when your peak usage of compressed air is, as well as when you are not using all of the air produced by your system.

When annual assessments are performed, you to have data to compare. If your kW increases over time, but you haven’t changed the demand, you will know there is an issue with something in your plant; whether that be leaks in your lines, faulty production equipment, etc. A compressed air system engineer will be able to take a deeper dive into the analytics and pinpoint the issues through a little extra work and testing. You’ve heard the phrase “You can’t manage what you don’t measure”.

  1. A data logger is connected to the incoming power of your compressor
  2. It collects data for 1 – 2 weeks.
  3. Data is brought back to our office and analyzed.
  4. We then review your compressed air usage together (e.g. what and when your peak usage is, when are you running out of air, and etc.)

What do our data loggers measure for you?

  • Pressure
  • Temperature
  • Moisture Dew Point
  • Flow
  • Amperage
  • Voltage

When your audit has been completed, this will help you determine the following 4 things:

Will you will benefit from a variable speed drive air compressor

    • Variable speed drive (VSD) air compressors vary the power supplied to the electric motor, thus allowing the speed of the motor to be efficiently controlled with the demand for air at any given point in time. On the other hand, a fixed speed compressor provides a constant power level to the motor, meaning that when the demand for air is lower, the efficiency is lower. For more on when to choose variable speed drive for your air compressor, read our blog.
    • If you have an existing rotary screw that is fixed speed, you may benefit from our ComEd Incentive Program which could save you thousands of dollars on a brand new air compressor!
  1. Duty cycle of the compressors
    • By measuring the voltage and amperage that your compressor uses throughout the day, data logging can determine how often and how hard your compressor is working. Every compressor has a standard kW value at regular PSI (e.g. 100), and if that standard kW value is being exceeded, the user can seek and fix any compressed air waste
  2. Leak rate
    • Data loggers can tell your system leak rate because they read the output of the compressor. Then you can add up the usual estimated usage of each piece of equipment that uses compressed air, and compare it to the output number. If these numbers are very close, you know your leak rate is very little. If these numbers are vast in difference, you know you have a large leak rate.
  3. Do you need to resize your equipment?
    • Data logging can help choose the size of a compressor in the case of an equipment replacement project. It is difficult to know if the current system is correctly sized or not, but taking a look at the system operation before buying new equipment can the cost and hassle of a mistake.
    • E.g. A 150 HP compressor needed replacement and was usually only running at 20%. Staff wanted to get a 30 HP compressor, but when looking at the results of the data logging, realized that there were times when the compressor spiked to 50% flow. They decided to go with a 100 HP VSD in order to meet their demand and stay energy (and cost!) efficient.


Other Services from Member

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System Assessment

A compressed air system that is not running at peak performance can cost you thousands of dollars a year in excess energy.