Compressed Air Audits

An audit evaluates how compressed air is produced, treated, distributed, and used. Its purpose is to identify performance problems and improvement opportunities using operating information rather than compressor size alone.

A pressure or energy problem can originate in supply, piping, controls, storage, or demand. Looking only at the compressor can miss the restriction or unnecessary use responsible for the problem.

Consider an audit before a major equipment purchase, after production changes, or when pressure and energy problems persist. Define the decisions you need the audit to support before agreeing on scope.

Gather equipment lists, operating schedules, utility rates, pressure requirements, maintenance records, and piping drawings if available. Identify the production areas experiencing problems and when those problems occur.

Depending on scope, measurements may include pressure, flow, power, runtime, loading, and air-quality indicators. Confirm the instrumentation, locations, and reporting period so the study answers your facility's questions.

The time depends on the system and required detail. Data collection should capture representative production cycles, shifts, and demand changes; a single brief reading may not describe normal plant operation.

Many operating measurements can be collected while production runs. Instrument installation or certain checks may need planned access or isolation, so confirm the fieldwork and any interruption requirements in advance.

It can help distinguish insufficient supply from distribution losses or demand peaks. Comparing readings at the compressor room and affected users provides more information than raising the compressor pressure setting.

No. A leak survey targets escaping air. A broader audit can also examine control strategy, storage, pressure losses, production demand, and compressor operation. Define which activities are included in the proposal.

Possibly. Correcting losses or operating problems may recover useful capacity. The measurements should establish whether existing equipment can meet required demand before recommending additional capacity.

Yes. Operating data can reveal how machines share load and respond to demand. Any proposed control changes should account for compressor capabilities and be verified after implementation.

Estimates should use measured operation, electricity costs, production hours, and clearly stated assumptions. Compare proposed changes with a representative baseline and distinguish expected savings from results already demonstrated.

No fixed return applies to every plant. Results depend on the opportunities found, implementation cost, production conditions, and follow-through. Request the calculation assumptions and a practical verification plan.

Agree on deliverables such as baseline findings, identified problems, recommended actions, priorities, estimated costs, and savings assumptions. The report should make clear what was measured and what remains an estimate.

Repeat relevant measurements after changes under comparable operating conditions. Check production requirements as well as energy use so an apparent saving is not simply caused by reduced production or lower service quality.

Call Process & Power at (901) 362-5500 to discuss your facility and goals. Explain whether the priority is pressure reliability, energy use, expansion planning, or evaluating replacement equipment.