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The audit staff at Compressed Ait Solutions is the most experienced in the industry. It is our goal to provide a comprehensive analysis of each
compressed air system and then provide a set of alternative solutions to the client. We then assist in evaluating those alternatives to select that which best suits the clients needs financially and operationally. Clearly
defining the existing air demand and electrical power requirements allows us to project the anticipated air demand after completing the recommended modifications and the power which will be required. We believe that to be
valid, an audit must record the performance of the system to allow independent verification if necessary. Our audit method includes designing specific solutions to problem compressed air applications in the production areas
as well as a complete analysis of the compressed air supply equipment and the overall system efficiency. Defining and estimating the cost of the recommended modifications allows us to provide a preliminary return on
investment based for determining the viability of a system upgrade project. We offer services through the implementation of the modifications, system startup, and savings verification.
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Systems Approach - Click here to view our audit brochure (910K)
If your plant is like most plants, your productivity depends on compressed air. Without it, production would slow down or shut down
entirely. Yet, compressed air remains one of the most neglected plant utilities, as most compressed air systems only receive attention when there is a loss of pressure or when a major piece of equipment
fails.
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The science affecting your compressed air system is widely misunderstood and typically
no engineering is applied to the design and operation of plant compressed air systems. The result is an inefficient compressed air system that does not adequately support production demand.
Compressed Air Solutions' Auditing Service will scientifically show you why your
compressed air system is not meeting production demand. And it often has nothing to do with the size of your compressed air system or the type of compressors you are using.
The results of Compressed Air Solutions’ Auditing Service routinely lead to major
increases in plant productivity and profitability, while improving the reliability and maintainability of your compressed air system.
Proving that your compressed air system is inefficient requires simple math. Showing you
where and how to improve the efficiency of your system requires the science of compressed air.
Compressed Air is Not Free
In most plants, compressed air is treated as though it were free. However, as with any
other production utility (i.e. steam, chilled water, etc.) there are direct costs and overhead costs associated with the production of compressed air.
So How Much Does it Cost to Operate Just One 100hp Air Compressor?
The cost for electrical power to operate this compressor (at an average rate of
$.10/kw-hr) is over $68,000 per year. Considering most plants have multiple compressors of various sizes and types, you can see how quickly power costs add up – but electrical
power is typically only 60%-70% of the total cost.
The Other 30%-40% of the Cost Includes:
· Maintenance and repair labor for the compressor room equipment, filters,
regulators, lubricators, drains, and other air control valves
· Replacement and repair parts required to operate and maintain the equipment
· Rental compressors and dryers
· Cooling water and water treatment costs
· Miscellaneous (insurance, administrative, benefits, house keeping)
Add it all up and the operating costs of just one 100hp compressor are about $75,000
year. In most compressed air systems, we find waste – inappropriate uses of compressed air, abandoned production equipment, excessive leaks and artificial demand. All of these
drive up system operating costs and do nothing to increase production efficiency.
Identifying and quantifying these opportunities to improve system efficiency is an
important part of Compressed Air Solutions’ Auditing Service. So that in addition to making system improvements we can justify the costs – typically providing a simple payback in 12-36 months.
Operating Cost Reduction Opportunities
Compressed Air Solutions’ Auditing Service is designed to reveal cost reduction
opportunities on both the supply side and demand side. However, only 1/3 of the cost reduction opportunities are usually found on the supply side or in the compressor room –
and at relatively high capital costs. The real cost reduction opportunities are out in the plant and generally require low capital expenditures.
Operating Costs and Sales
Think in terms of product sales and profitability. In order to justify $100,000 in operating
costs, you have to have $1,000,000 in sales at a 10% profit. So in this case a 30% reduction in operating costs would translate into a $30,000 increase in bottom-line profits,
Focused on the everyday production cycles of your compressed air system, Compressed
Air Solutions’ Auditing Service does more than simply identify your compressed air related problems – we solve them.
Compressed Air Solutions Auditing Methodology
The analysis of your compressed air system is a critical component of Compressed Air
Solutions’ Auditing Service. A typical analysis requires less than one week of on-site time and consists of the following procedures:
1. Determining the actual capability and condition of the individual supply equipment
including the compressors, dryers, filters, cooling systems, etc. The relationship of actual efficiency to design efficiency sets the short and long-term priorities for the supply equipment.
2. Measuring the storage capabilities of the system and its relationship to the changes
in air demand that occur in the system. Determining the demand event sizes and comparing them to the relationship of supply power and storage is key to stabilizing the
system pressure and often provides major opportunities for efficiency improvement.
3. Evaluating the air users in the system including waste, leaks, artificial demand, and
inefficient applications.
4. Analyzing and providing solutions to correct applications that are not performing
adequately. Correcting applications that require excessive pressure to enhance productivity and provide the flexibility required to operate the supply system at peak efficiency.
5. Creating a process flow diagram that depicts the general arrangement of your
compressed air system, as well as the supply power and demand volume in all operating conditions.
6. Determining the total operating costs of the system including energy, maintenance,
labor, cooling water, etc. Calculating the efficiency of the system in terms of costs vs. air demand will allow us to compare your system to ideal industry costs. Projecting the
operating costs for the proposed arrangement will allow us to calculate a return on investment for the recommended improvements to your system.
7. Developing a prioritized action plan with capital costs and estimated installation
costs for the proposed modifications to your system.
8. Providing a complete report including process flow diagrams and/or illustrations to
assist in the installation and implementation of the proposed arrangement.
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