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For years, people have always assumed that compressed air is free, it cannot be seen nor does it make a mess when it leaks so there was never a cost associated with it. Now with rising energy costs, more and more people are realizing that not only is it not free but it is one of the most expensive utilities in plant.
Using the ASME standard EA-4-2010 Energy Assessment for Compressed Air Systems we take a system wide approach to reviewing your compressed air needs and assets. Our data collection equipment is specifically designed for compressed air as are the software programs we use to model your system. Using the Airmaster software program, we can baseline your current compressed air consumption and then model various scenarios in the program to find the solution that best meets your current and future needs. We also examine your distribution system,(piping), as well as your end uses to make sure you are using your compressed air supply in the most efficient and practical ways. See the chart below:
As you can see, actual production only accounts for half of the air produced, the rest is for the most part wasted. Can we eliminate all of this? No, however if we are proactive and manage it we can realize savings.
Looking at it from another perspective, let’s say we have a plant that operates 24 hours per day, seven days per week and uses approximately 500 cubic feet per minute, (CFM) of compressed air. This would equate to a 100 Hp air compressor. Let us also assume that this company has an electrical cost of $.06 per kilowatt hour. His annual electrical cost only for this compressor would be right around $40,000.00. That would mean that $20,000. 00 is for production, $10,000.00 for leaks $6,000.00 for artificial demand and $4,000.00 for poor practices. If we can identify and eliminate half of these problems we can generate an annual saving of $15,000.00. Typical compressed air audits identify savings of 15%-30% on most compressed air systems with an initial payback for the audit of less than one year.
Using our Airmaster Software, we show how the system operates over a typical 24 hour period for the full time the data is collected.
We also break the system down to show what the power consumption and capacity are during the data collection period.
We look at the system as a whole to determine the best overall options for savings and show you these options in a comprehensive report. A typical Return on Investment Table is shown below.
After we complete a baseline study, we can then help you formulate a plan to better manage your compressed air system now and into the future. As well, we work closely with the local Provincial Utilities and Efficiency Organizations to help you achieve maximum rebate potential on your compressed air projects.
Ultrasound leak detection covers a wide range of leaks: pressure or vacuum and any gas. Sound dependent, ultrasound instruments detect the turbulent flow produced as the fluid (liquid or gas) moves from the high-pressure side to the low-pressure side of a leak. Ultrasound leak inspection is especially beneficial in areas where there is a saturation of gases or where a wide variety of gases, pressurized vessels and vacuum processes exist. For this reason ultrasound leak detection is used in many facilities for safety, environmental, energy or quality assurance programs. Utilizing UE Systems patented software for compressed gas leaks users are able to analyze and report on cost reduction while demonstrating the reduction of a plant’s carbon footprint.
A major advantage to ultrasound leak inspection is that as a high frequency, short wave signal, ultrasound emissions tend to be localized around the leak site. By scanning an area with an ultrasound instrument, a user will follow the sound of the leak to the loudest point. Once identified, the leak amplitude can be noted and used in UE Systems’ compressed gas reporting tool for reporting, cost analysis and environmental impact.