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HEALTH CHECKS & ENERGY AUDITS IT’S TIME FOR A HEALTH CHECK


There is little doubt that compressed air health checks, energy audits and leak detection can have a transformative effect on business operations


Atlas Copco Compressors have developed three levels of health checks and energy audits for compressed air installation. Some of these services are offered free-of-charge, while others require an upfront investment which is quickly recouped through energy efficiency improvements, and the subsequent cost savings they bring: Level 1 – Free visual inspection and energy


potential calculations (EPC): • A visual assessment covers information


such as compressor room environment, determining any air quality issues, and a visual inspection of all compressed air equipment on site, including appropriate capacity, ISO compliance, unproductive running, and pressure levels. • This procedure results in a summary of


Paul Clark, Business Line Manager, CTS Sales, explains how compressed air systems health checks and energy audits can reduce costs, improve environmental performance, and help deliver energy efficiency improvements


financial and environmental reasons. Cutting electricity use across the shopfloor can significantly reduce monthly energy bills, with the savings going directly to the bottom line. Using less energy is also critical to long-


T


term sustainability efforts. There is a growing number of companies embarking on a journey to net-zero by implementing initiatives that provide incremental value and savings over time. Even the most conservative analyses


estimate that compressed air systems account for 10 per cent of all energy used in global industry, and of that, between 10 – 30 per cent is wasted on leaks. This wastage is expensive; even a 3mm leak could cost around £2,000 a year, with a loss equivalent to 16 tonnes of CO2 emission. So, any optimisation of compressed air systems – no matter how small – impacts performance and efficiency significantly, lowering fuel bills and reducing carbon footprints. But how do plant managers ensure that a


compressed air system is operating to its full potential? How do they identify and eliminate air leaks, optimise performance, reduce energy consumption, and drive down costs? The simple and most effective means of


achieving these goals is to carry out a health check and energy audit. These assessments can be performed quickly and accurately, and in some cases at no cost, and with zero


50 APRIL 2022 | PROCESS & CONTROL


here is little doubt that energy efficiency remains a top priority for most manufacturing organisations – for both


disruption to the users’ production operations. Just one important aspect of these checks is identifying and eliminating leaks Leaks can be caused by many issues


including corrosion, poor pipe connections and bad seals. And without investigation, these problems can add up to a significant amount of wasted energy over time. There is a variety of techniques that can be


employed to locate, log, quantify and rectify air leaks. Initial steps involve little or no technology. In fact, some leaks can be found simply by listening and their location can be identified by applying a soapy water solution to potential leak points such as joints, flanges, and valves, with bubbling indicating the source. A more precise approach employs


advanced technology; the use of ultrasonic leak detection equipment, which operates without interrupting plant production, reaches system areas that are hard to access, and locates all air leaks. Furthermore, acoustic imaging cameras are more effective and can help detect leaks up to ten times faster than traditional methods. Once inspection has been completed, leaks


can be marked on-site with weatherproof tags, along with a supporting written report that can provide more details on leak locations, photographic evidence of holes, leak severity in litres/minute, energy costs, positions, and costs to repair. With the technology in place to provide fast, accurate and cost-effective leak detection,


equipment health, outlining running equipment improvements, as well as wasteful practices or non-conformance with ISO standards. • EPC calculations can also be carried out,


focusing on the power usage of the compressors, load v. unload hours, and average leak assessment. This calculation identifies whether there is a requirement for a Level 2 assessment and provides an indication of the tangible savings that it would bring. Level 2 - Energy assessment and


recommendations through data logging: • While EPC delivers an estimation of


potential energy savings, this next level service provides a real-world assessment based upon the findings of data logging equipment fitted to each compressor. The data logging devices record and then map the energy consumed over a full week period, showing the actual running hours and calculated air usage. • Based on this data, engineer specialists


can then calculate a realistic energy savings potential, make simulations, and provide recommendations to achieve optimal energy efficiency. This service can also be free of charge and always provides high-quality, actionable insight. Level 3 - Full audit to ISO 11011:2013


standard: • The full audit service provides a premium


assessment of a range of parameters, such as flow testing, air leak detection, air quality testing, measurement and analysis of pressure and dewpoint throughout the wider system, from compressor room to production processes. Included in the audit is reporting and discussions of the most suitable methods to reduce energy costs and CO2 emissions. To ensure that installations are assessed


based on a clearly defined framework, an energy audit should follow the ISO 11011: 2013 standard. This sets requirements for conducting and reporting the results of a compressed air assessment, one that has


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