No knowledge, no improvement
August 10th 2009

Without a thorough understanding of what is happening to your compressed air system it is not possible to make improvements.By conducting an assessment or audit it is then possible to identify areas for increased efficiency explains BCAS

A recent BCAS study of compressed air systems found among other things that:

• 75% of compressed air system operators had no formal training in compressed air system efficiency.

• More than 35% of those interviewed reported unscheduled system downtime during the previous 12 months. For 60% of those the breakdown lasted 2 days or longer.

• More than 50% had taken no action over the previous 2 years to improve efficiency – not even a leak maintenance program to reduce leakage which is the largest single source of wasted energy in a typical compressed air system.

A Survey or Audit is a snapshot of the compressed air system under the loads and assumed demands at the time of the survey.

An Assessment is a service designed to measure the loads of the system on both the supply side and the demand side so that it can be managed more effectively.

These should never be used as a shortcut to sell you more equipment. They are a means to determine how well your current system is being utilised and where the improvements can be made.

Energy cost reduction is usually the driving force behind Audits and Assessments however other benefits of having an audit or assessment of your compressed air system performed are:

• improved plant and process productivity

• improved product quality

• improved equipment reliability

• reduced maintenance costs, reduced scrap rates and reduced costs

The success of a survey, audit or assessment requires three major elements:

• knowledge

• planning

• follow-through

Knowledge requires an understanding of the compressed air system on a wide scale, including all the subsystems and components. What are the sizes, types, and ages of the compressors? Have they been properly maintained? What about traps and drains? Are pressure gauges working, and if so, do they indicate adequate pressure for the various areas of use? What are the assigned pressures for these areas? Can some compressed air applications be replaced by other methods? For example, instead of using compressed air for cooling, drying, or cleanup, low-pressure blowers or fans may suffice.

Planning incorporates elements such as a written scheme of the compressed air system and its various components. This is a mandatory requirement under the Pressure Systems Regulations and if you do not have one contact BCAS for advice. Planning also includes scheduling of the survey. Break up the survey so that it can be performed without negatively affecting production and other maintenance responsibilities of the personnel assigned to the task Follow-through is possibly the most important factor.

If a leak is not repaired, all the effort and cost of the survey is wasted. Therefore, use a follow-up method to ensure that all identified leaks have been repaired and other actions taken. In addition, when a leak has been reported as fixed, the repair should be checked.

Sometimes the repair might cause another leak to occur or the wrong component may have been ‘repaired’. Follow-through includes a review of the survey, cost analysis, and, when possible, environmental impact analysis. A report can then be generated to demonstrate the effectiveness of the survey and the related cost savings benefits.

To find out how membership of BCAS can help you and your company with compressed air system audits and assessments, email enquiries@bcas.org.uk or visit www.bcas.org.uk

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