Compressed air audit.Optimization of the operation compressed air systems

The efficiency of compressed air production increases when the pressure level decreases. Just reducing it by 1 bar can result in energy savings in the range of 6-8%. However, it is important to remember that specific technological processes or end-users may require a certain minimum level of compressed air pressure.

There are several options to lower compressed air pressure values in a company and reduce energy consumption, including:

• Regulating with mechanical switches on compressors involves installing a pressure switch in the system. This switch includes a pressure differential sensor, and its components control the operation of the compressor.
• Regulating by introducing variable-speed compressors into the system, which use a frequency inverter in the circuit. This is also the most efficient solution.
• A system with multiple compressors, each with different power, and a control system for them – known as a cascade – allows only those compressors to operate for which we currently have a demand in the company. As a result, only compressors with the desired, specified efficiency are activated for operation.

Let’s remember that improperly selected installation and inadequate maintenance of the installation and machinery can also be responsible for high compressed air pressure. Lowering the pressure reduces the risk of compressed air leaks.

At Energy Trend, we will carefully examine how we can optimize the operation of your compressed air installation.

Compressed air system audit is an essential element in improving the energy efficiency of industrial facilities. As part of the audit, a comprehensive testing and verification of system components are conducted. The audit aims to determine the correct operation of individual components, detect potential damages and leaks, and determine the extent of losses caused by them in the compressed air system, which delivers compressed air at pressure from the compressor to the devices.

The basic industrial components of a compressed air installation include compressors, compressed air treatment systems (comprising coolers, dryers, filters, separators), a pressure tank, and the network of pipelines used for air transport. During the audit, measurements of compressor performance, workload, air production quantity, power values, and equipment configurations are conducted. An important aspect of the audit is also the verification of air-tightness, which allows even the smallest defects to be detected. Additionally, spot measurements of compressed air pressure are taken at several key points in the installation.

The audit results are compiled into a report, which… includes measurements, a description of identified issues, and an estimate of the costs of corrective actions. This report serves as the basis for planning the optimization of compressor operation and improving the energy efficiency of the installation. It’s worth noting that a compressed air audit is not a standard examination, and each case requires an individual approach and adaptation to the specific characteristics of the installation and equipment.