This audit could be conducted visually as well as with a data logger device, without any disruption to your production. The visual audit exercise is intended to flag-up ‘quick-win’ opportunities to fix costly air leaks and address inefficient operating practices. Few such practices are continuous running of compressors during periods of low demand like evenings/ weekends and therefore, heavy power loss in Idling and blow-off with under-utilization of a costly asset. The other type of audit is conducted with a data-logger device by measuring real-time current consumption of the air compressor by certain assumptions and parameters. The results of this study give you an opportunity to explore more efficient options before making a capital purchase. This audit will also help you to achieve your power savings goals and carbon footprint reduction, thus reducing the environmental impact of its operations. This power audit will not disrupt your facility’s operations but rather is performed while the equipment is running. After setting up, the data logger device is left to operate for a one-week period and has three major steps.
Step 1: Real-time current measurement (ii-Trak measurement)
To investigate the potential savings in your compressed air plant, the first step is to perform a data-logging exercise by measuring real-time current consumption. This activity needs hardware installation which usually takes less than 30 minutes and a measurement period of 1 week.
Step 2: Simulation and assessment
A sample size of 1 week provides a fair assessment of the air usage in the plant which can be then extrapolated for the year to calculate potential savings. Based on the logged data and the sample, the simulation is done with the two assumptions:
- The sample is a fair depiction for a yearly consumption.
- Power cost remains constant throughout the year.
The recorded data will then thoroughly analyzed that gives a scientific recommendation on improvement areas. and the best solutions are recommended by the team of air experts. Some of the recommended solutions are modifying the parameters of operations i.e. pressure settings or Variable Speed Drive (VSD) compressors.
Step 3: Report and recommendations
A detailed report will be generated with the current scenarios, conclusions, and recommendations that help you to take appropriate actions/decisions from the simulated data. These actions implemented out of this study can also help in subscription to PAT scheme and ISO 50001 compliance.