Compressed Air Audits by JHFOSTER
Did you know your compressed air system accounts for 10 to 15% of your facility’s total energy bill and half of that is likely being wasted? As your air compression partner, a JHFOSTER compressed air audit can help you uncover hidden waste, reduce costs and transform your system into a model of efficiency.
What is a Compressed Air Audit?
Compressed air audits provide a comprehensive evaluation of your entire compressed air system from generation to point of use that identifies specific opportunities to reduce energy consumption, improve system reliability and enhance air quality.
Compressed air audits reveal costly inefficiencies, such as:
- Leaks
- Incorrect or improperly sized piping
- Malfunctioning or improperly specified equipment
- Control issues
- Improperly sized or configured compressors
- Issues with poor air quality
Pinpoint Inefficiencies and Unlock Savings
JHFOSTER’s compressed air audit service identifies:
System leaks: Leaks are a primary source of wasted energy. A single 1/4-inch leak in a compressed air piping system can cost a facility between $2,500 and $8,000 annually. Identifying and fixing leaks provides a significant reduction in energy bills.
Undersized equipment: When air compressors or air delivery pipes are too small, the system must work harder to supply enough pressure to connected tools and equipment. This increases energy consumption and causes wear and tear, which can reduce compressor lifespan. Ensuring that equipment is properly sized minimizes electric bills and repair and replacement costs.
Inefficient controls: Outdated or malfunctioning controls cannot effectively control a compressor, reducing performance of end-point tools and increasing energy consumption. Outfitting the system with proper controls optimizes system efficiency and ensures pneumatic equipment operation.
Air quality issues: Malfunctions with filtration and drying systems can introduce corrosion, contaminants and moisture into the system, degrading air quality. Making recommended adjustments to these components ensures clean, dry air and finished product quality.
Optimization opportunities: Malfunctioning and improperly sized components, air leaks and system contamination all degrade the efficiency, performance and useful life of the air compression system. Identifying and addressing issues before they cause problems increases system availability and lengthens equipment lifespan, providing long-term efficiency and operational improvements. JHFOSTER auditors will make recommendations for modernizing equipment and improving your system design.
Additional Benefits of a JHFOSTER Compressed Air Audit
Beyond maximizing the efficiency of your system, there are additional benefits to having a compressed air energy audit performed, including:
Improved quality. An air audit will catch and address clogged filters and malfunctioning dryers so contaminants are removed, ensuring that your air and finished products are of the highest quality.
Reduced energy bills. When energy costs associated with the compressed air system are rising, an audit can reveal simple changes and quick fixes that provide rapid reductions in energy bills.
Less downtime. Air audits identify potential equipment malfunctions before total failure, reducing system – and facility – downtime.
Longer operational lifetime. Broken and incorrectly sized parts put a strain on your air compression system. By catching and tending to issues before they cause extensive wear and tear, you extend the lifetime of your equipment.
Our 4-Step Compressed Air Audit Process
Compressed air energy audits can be performed without disrupting production. A full-system audit led by JHFOSTER’s air compression professionals includes leak detection, data logging, pressure, power and flow rate measurements, as well as recommendations for improving efficiency and preventive maintenance activities.
This type of full-system audit takes one to two weeks, but will reveal efficiency and operational improvements that can reduce the facility’s current electric bill by 10 to 50%. Utility providers may offer rebates and incentive programs to help offset the cost of professionally performed audits.
JHFOSTER’s audit process follows these four steps:
Step 1: Site Survey: Our specialist will conduct a walk through of the facility to map your entire system, including all components and their current configuration. Our auditor will determine how the components interact with each other and will identify obvious system flaws.
Step 2: Data Logging: During the site survey, we install data logging equipment throughout the system to measure energy usage and air pressure. The measurement period should be at least one week and should include periods of normal operation, downtime and peak and non-peak usage.
Step 3: Data Analysis: Our engineers analyze the collected air study data and create a detailed profile of your system’s performance, identifying specific areas of waste and inefficiency.
Step 4: Actionable Report: You receive a comprehensive report detailing our findings, clear recommendations for improvement, projected energy savings, ROI and information on available utility rebates.
Frequently Asked Questions
How much does a compressed air audit cost?
While costs vary by system size, the investment is often recovered quickly through energy savings and utility rebates.
How often should I have my system audited?
Because air audits can help maintain peak efficiency and prevent major issues, an audit is recommended every three to five years or sooner if you notice changes in performance. Industries with very high air purity requirements may require more frequent audits to ensure air quality.
What is compressed air testing?
Air testing involves collecting air samples and analyzing them for contaminants, such as particulates, oil and moisture, to ensure that generated air meets system, application and regulatory requirements. Air testing may be a component of your compressed air audit or a separate service. JHFOSTER offers compressed air quality testing to help companies meet ISO 8573-1 standards for air purity.
Start Operating Smarter. Schedule Your Air Audit Today.
Stop wasting money on an inefficient system. As your partner, JHFOSTER auditors are ready to help you unlock energy savings and achieve top-notch performance from your air compression system. Get in touch today at 855-688-0043 to schedule a compressed air system evaluation.