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Compressed Air System Analysis

Developed by William Scales and David M. McCulloch
for the Compressed Air Challenge

As participants of the Compressed Air Challenge

Fundamentals of Compressed Air Seminar
learn, a compressed air system analysis can highlight
the true costs of compressed air and identify
opportunities to improve efficiency and productivity.
Compressed air system users should consider using an auditor to analyze their compressed air
system. A number of firms specialize in compressed air system analysis, and electric utilities,
equipment distributors and manufacturers, energy service companies and engineering firms,
also perform it. When selecting a service provider, it is important that factors, in addition
to price, be considered, says Niff Ambrosino, chief operating officer of Scales Industrial
Technologies and a CAC Fundamentals and Advanced Instructor. The qualifications and
capabilities of the audit technicians, and reputation in the local industrial community are
key and should also be considered.

The Compressed Air Challenge (CAC) is pleased to announce

the third session of Fundamentals of Compressed Air
Systems WE (web-edition) on September 13, 2010. Led by
Frank Moskowitz and Tom Taranto, this web-based version of
the popular Fundamentals of Compressed Air Systems training
uses an interactive format that enables the instructor to diagram
examples, give pop quizzes and answer students questions in
real time. Participation is limited to 25 students. Please visit
www.compressedairchallenge.org to access online
registration and for more information about the training.

Fundamentals of
Compressed Air
Systems WE

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If you have additional questions about the new web-based

training or other CAC training opportunities, please contact
the CAC at [email protected] or
call 301-751-0115.

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CO2

When selecting a service provider, it is important

that factors, in addition to price, be considered
Niff Ambrosino, Chief Operating Officer of Scales Industrial Technologies
and a CAC Fundamentals and Advanced Instructor

An informed consumer should be aware that the quality and comprehensiveness of system analysis can vary.
Independent auditors should provide recommendations that are systems-neutral and commercially impartial.
Independent auditors should neither specify nor recommend any particular manufacturers products.
A comprehensive compressed air system analysis should include an examination of both air supply and usage,
and the interaction between the supply and demand. Auditors typically measure the output cfm of a compressed
air system and the input kW, calculate energy consumption in kilowatt-hours and determine the annual cost
of operating the system. The auditor may also measure total air losses caused by leaks and locate those that
are significant.
All components of the compressed air system are inspected individually and problem areas are identified. Losses
and poor performance caused by system leaks, inappropriate uses, demand events, poor system design, system
misuse and total system dynamics are calculated, and a written report with a recommended course of action
is provided.
It is critical for compressed air system assessments to investigate the individual system components, the component
interactions and the entire compressed air system as a whole, says Greg Harrell, Ph.D., P.E. of Energy Management
Services and a Certified CAC Fundamentals instructor. Focusing on compressor controls, air dryers, end-use
equipment, leaks and the interactions of all the components are all essential parts of an effective compressed
air system management strategy. As an example of the necessity of the system focus consider a leak abatement
program, he continues. Significant attention could be given to eliminating leaks. However, if the compressor
control strategy does not allow the compressors to efficiently reduce energy consumption in response,
then this reduction may yield minimal benefit.
The Compressed Air Challenge (CAC) has developed guidelines to define two levels of system analysis services,
independent of the type of firm offering these services. More information on these services can be found in the CAC
Guidelines for Selecting a Compressed Air Service Provider. An excerpt of these guidelines appears below.
For a full copy of these guidelines, visit www.compressedairchallenge.org or purchase CAC Best Practices
for Compressed Air Systems (This 325-page manual is available at our bookstore):

www.airbestpractices.com

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C ompressed A ir S ystem A nalysis

kW

Overview of Levels of Analysis of Compressed Air Systems

The following levels of analysis of compressed air systems have been developed in an effort to
provide commonality of terminology, methods and procedures to be used by service providers,
as well as the results to be expected by end users. Energy utilities are actively involved in these
efforts, and some provide incentives to use these analyses to improve the energy efficiency of
compressed air systems.

CO2

It is critical for
compressed air
system assessments
to investigate the
individual system
components, the
component interactions
and the entire
compressed air system
as a whole.

Greg Harrell, Ph.D., P.E. of Energy

Management Services and a Certified
CAC Fundamentals instructor

There are two levels of analysis: a basic assessment and a comprehensive audit. Conducting
a basic assessment is the first step in analyzing a compressed air system. Depending
on individual needs, this can be conducted either by trained plant personnel or by an
experienced compressed air system services provider. A basic assessment is not intended
to provide the level of detail found in a comprehensive audit, but significant reductions in
energy (25% or more) and lower maintenance costs often result from a basic assessment
alone. Once initial opportunities have been identified, you can decide whether additional
analysis services are required to further define system dynamics and corresponding system
improvement opportunities. This decision will depend, in part, on the size and complexity
of the system being examined (both supply and demand) and whether critical issues requiring
further investigation to identify their causes and potential remedies surfaced during the
evaluation.

Basic Compressed Air System Assessment

A basic system assessment of a compressed air system is the first level of analysis. Depending
on the complexity of the system, a basic system assessment can be conducted by either
trained plant personnel or by an experienced compressed air system efficiency expert.
Using readily available data combined with limited measurements, an expert can identify
system inefficiencies and make recommendations that will result in energy cost reductions.

CAC Qualified Instructor Profile

Niff Ambrosino
Scales Air Compressor Corp.
185 Lackawanna Avenue
W. Paterson, NJ 07424
Ph: (973) 890-1010
Fax: (973) 890-7343
Email: [email protected]

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www.airbestpractices.com

Niff Ambrosino is chief operating officer for Scales Industrial Technologies, one of the nations
leading compressed air systems distributor and service companies. With over 38 years in the
compressed air industry, Niff has in-depth experience working as a shop rebuild mechanic,
field service technician, sales engineer, energy auditor/surveyor and manager. Niff is a certified
Level I and Level II Compressed Air Challenge instructor, has trained sales/service personnel
and conducts compressed air system seminars for end users.

Production downtime and maintenance costs also may be reduced. Basic system
assessment of the facility could reveal:

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pp Potentially inappropriate uses of compressed air

pp Significant leaks
pp Processes or individual end-uses most sensitive to low pressure
pp System instability
pp High-volume and intermittent uses
pp Capacity control problems
pp Maintenance and reliability issues

Comprehensive Compressed Air System Audit

There are two levels

of analysis: a basic
assessment and a
comprehensive audit.

A comprehensive system audit is the top level of system analysis, conducted by an experienced
compressed air system auditor. It is a detailed analysis of the entire compressed air system,
and may have been preceded by a basic system assessment. Measurements and data logging
are generally part of comprehensive compressed air system audit procedures.
The customers objectives and system problems will be discussed prior to the start of the audit,
and the proposed procedures also will be explained. The objective is proper management of
the complete compressed air system for optimum efficiency and reliability. This includes
alignment of the supply side (compressors, their controls, aftercoolers, dryers, filters and
primary air receivers) with the demand side (distribution piping system, secondary air
receivers and all of the end-uses of compressed air, including leaks), in conjunction
with the needs and financial objectives of the business unit.

CAC Qualified Instructor Profile

Greg Harrell, Ph.D., P.E.
Energy Management Services
341 Willocks Drive
Jefferson City, Tennessee 37760
Ph: (865) 719-0173
Email: [email protected]

Greg Harrell is a certified Level I Compressed Air Challenge instructor. Dr. Harrell
has conducted many energy surveys for industrial clients throughout the world and
is also a primary instructor in the North Carolina State University Energy Management
Diploma Program.
The instructors featured here are available to lead a Compressed Air Challenge
seminar at your facility. Visit www.compressedairchallenge.org for more information.

www.airbestpractices.com

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kW

C ompressed A ir S ystem A nalysis

CO2

A comprehensive system audit is the top level

of system analysis, conducted by an
experienced compressed air system auditor.

The auditor should accomplish the following during a comprehensive audit:

1. Establish a baseline, against which the results
of any proposed changes are measured.

9. Establish a controls strategy through real-time

analysis.

2. Draw a block diagram and a review of the

compressor room to determine present compressor
operations, control strategy and the storage capacity.

10. Identify customer approach to air leak detection and

repair and make recommendations for improvement.

3. Record compressor and dryer pressures

and temperatures.
4. Validate end-use pressure and quality requirements.
5. Conduct data logging of readings of power and
pressure (and flow, if applicable) throughout the
system for a more in-depth analysis of the dynamics
of the system and resulting problems. Provide graphs
showing data collected over time.
6. Construct a demand profile to identify significant
end-uses and their impact.
7. Construct a pressure profile to identify what
determines the system operating pressure
and to identify possible changes.
8. Review primary and secondary air receiver capacities.

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11. Review differences in shift operations and impact

on air use.
12. Identify compressed air end-uses which may be better
served by other means and recommend suitable
alternatives.
13. Compare air quality provided for each end-use
with what is really needed and make appropriate
recommendation(s).
14. Review maintenance procedures and training.
15. Review initial verbal proposals with all who attended
a pre-audit meeting to obtain buy-in from all
departments involved.
16. Provide a comprehensive written report of all
findings, recommendations, and results.

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Working Together for Compressed Air Best Practices

Compressed Air Best Practices is a technical magazine
dedicated to discovering Energy Savings and Productivity
Improvement Opportunities in Compressed Air Systems for
specific Focus Industries. Each edition outlines Best Practices
for compressed air users particularly those involved in
managing energy costs in multi-factory organizations.
Utility and Energy Engineers, Utility Providers and Compressed
Air Auditors share techniques on how to audit the demand-side
of a system including the Pneumatic Circuits on machines.
This application knowledge allows the Magazine to recommend
Best Practices for the supply-side of the system. For this
reason we feature air compressor, air treatment, measurement
and management, pneumatics, blower and vacuum technologies
as they relate to the requirements of the monthly Focus Industry.

n Compressed Air Users Focus Industry

A. Energy and Utility Managers share experiences
B. Audit case studies and Best Practice recommendations
n Utility Providers & Air Auditors
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n Compressed Air Industry
A. Profiles of Manufacturers and Distributors
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To subscribe visit www.airbestpractices.com

International pricing for print edition $65 in Canada and $95 for other countries.