Compressed Air System Analysis

Most facilities are spending too much money on energy costs. Unlock energy savings today with a compressed air system analysis.

Worried you’re spending too much on your monthly utility bills? AP Energy performs in-depth analyses to ensure you’re getting the most out of your compressed air systems.

What Is Compressed Air System Analysis?

A compressed air system analysis is an isolated look into the operational efficiencies of an air compressor system. Compressed air is a vital process of most industrial manufacturing operations. The reliability of keeping a compressed air system pressurized is essential, and without it, much of the industrial sector’s production lines will stop if their compressed air system fails. As a result, reliability is much more critical to facilities than energy efficiency.

AP Energy always does an energy analysis before making any recommendations at a facility. We look for things like:

  • Capacity redundancy: Does the facility have a back unit or plan to mitigate downtime of the facility? What is the response time of the backup plan, and when was the last time this backup plan was verified as operational?
  • Water: Water in a compressed air system, or liquid condensate, is typically an indicator of a larger equipment issue and, if not taken care of, can cause other reliability issues downstream.
  • Stable pressure: Most of what causes production equipment to stop is when the pressure drops. Many production lines even have alarms to halt a process when the pressure drops below the desired point to avoid quality issues.
  • Expansion plan: When production increases in a facility or new lines are added, the plant checks to ensure they have the air capacity to meet the new process. But planning for those changes is also important, so the change is energy efficient. The array of equipment isn’t always conducive for an easy increase in fixed or variable demand and can cause operational problems.
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Since 1986, AP Energy has been providing businesses with full system audits to save money and ensure system efficiency.

What Do Technicians Look For in a Compressed Air Audit Procedure?

A compressed air audit is essential, making sure your systems work efficiently. When systems go a long time without preventative maintenance, you could be spending more money than you need to on your monthly energy bills. When you hire an AP Energy technician to come and check your compressed air systems, we evaluate:

  • Existing air compressors: Our technicians ensure air compressors were installed correctly and that they’ve remained in good condition.
  • Energy-saving opportunities: Your AP Energy expert reviews your system to guarantee you’re conserving as much energy as possible.
  • Compressed air quality: Evaluating air quality equipment such as air cooler, dryers, filters, drains, etc., ensures that the air distributed in the facility isn’t toxic to you and your workers.
  • Equipment fit: AP Energy technicians check each aspect of the system—particularly the piping distribution system—to make sure everything fits correctly. A piece of equipment that’s too big or small can result in surplus energy usage.
  • Demand-side control systems: Demand-side control systems are one of the most overlooked areas of the compressed air system. Reviewing this is beneficial for energy efficiency, unit longevity, and maintaining your company’s bottom line.
  • Pressure drops: Areas of low pressure and insufficient air distribution are among the most recognized signs of issues in your compressed air system.
  • Cost of energy: Similar to drops in pressure, increased energy bills are one of the first signs of a problem in your compressed air system. AP Energy conservation experts help you go over your energy bills; this is essential to understanding where there may be inconsistencies in your system.

How To Improve Compressed Air System Performance

A compressed air system analysis is essential to maintaining efficient system performance. In addition to the assessment, here are five other things to consider when it comes to improving the performance of your system.

  1. Participate in awareness training: Awareness training is a good first step to improving air system performance and lowering energy costs. As employees are more engaged and educated about facility operations, they are more mentally aware of their actions.
  2. Continuously monitor your system for inconsistencies: When you notice an increase in utility bills or that the air pressure isn’t as strong as it usually is, this is a good indicator that there’s an issue with your system. Understanding your bills and taking note of a change in system efficiency can expand the lifespan of your compressed air system.
  3. Install high-quality compressors and dryer controls: Investing in cheap compressors and dryer controls can negatively impact the lifespan of your compressed air system. Your compressed air system is an investment and should be treated as one.
  4. Replace equipment as necessary: If you notice a broken piece of equipment, don’t hesitate to replace it. Being proactive with your compressed air system components ensures that you are operating reliably and efficiently.
  5. Lower air pressure: Bigger doesn’t always mean better. Lower air pressure might be more efficient for your operations for smaller facilities and can result in significant energy savings.
Quality Compressed Air Leak Audit & Management Consultants

Boost the Efficiency of Your Compressed Air System With AP Energy

AP Energy has helped Ohio-based industrial facilities like yours boost the efficiency of their compressed air systems through an in-depth compressed air system analysis. Our compressed air system analyses are performed by energy experts that evaluate all areas of your system, including existing air compressors, air quality, pressure drops, cost of energy, and more.

We’ve made a significant impact on industrial facility energy saving, but don’t take our word for it—see how we’ve helped our clients improve their compressed air system performance! Save money and converse energy by connecting with us today to get started on your next compressed air system analysis.

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Independent and brand-neutral, our loyalty lies with delivering the best results for the client. Count on AP Energy to deliver the solutions to optimize your energy usage.