Plant & Works Engineering April 2022

32 | Plant & Works Engineering www.pwemag.co.uk April 2022 Process, Controls & Plant Focus on: Compressed Air 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. Energy audits and ISO 11011: 2013 standard 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 considered the entire system, from energy inputs to the work performed as a result of these inputs. It can also serve as a benchmark for ISO 50001 certification that demonstrates an organisation’s commitment to continual improvement in energy management. But this essential role is not universally accepted in some complex operating environments, where it is easy to overlook the importance of high- performing compressed air systems. Common misconceptions around air energy audits and leak detection Failure to instigate compressed air health checks and energy audits can also sometimes be based on outdated misconceptions that do not reflect real-world experience. Here are some of the most common fallacies: “I don’t have any compressed air leaks in my manufacturing facility” Even the most modern compressed air system is likely to have some level of leakage within six months of installation. Manufacturing facilities are often harsh operational environments. Over time, leaks can occur due to factors such as human error, sub-standard welding or pipe connections and damaged valves and seals. Often, it is not possible to know that leaks exist unless they are looked for, which is why leak detection surveys are crucial. “Health checks and energy audits will disrupt my production lines” Again, this assumption is untrue. The initial steps, such as a health check, couldn’t be easier and involve a visual assessment that can be conducted in as little as 10 minutes, with no downtime whatsoever. By its very nature, this type of exercise is intended to flag-up ‘quick- win’ opportunities, enabling end-users to fix costly air leaks and address inefficient operating practices. Even more sophisticated data logging and ultrasonic testing, and the fitting of flow meters, can be performed in a completely unobtrusive manner. “Compressed air audits and leak detection surveys will cost me a lot of money.” Many of the air audit services offered by compressor equipment suppliers are free of charge. Even when there is an upfront cost the efficiency savings discovered always amount to more than the initial outlay. Indeed, far from being a drain on resources, air leak detection surveys can in fact facilitate significant energy bill reductions with returns dwarfing any expenditure. Audits and health checks can also deliver significant savings on the installation of new equipment, eliminating the risk of over-specification. Transforming business operations There is little doubt that compressed air health checks, energy audits and leak detection can have a transformative effect on business operations. There are experts on hand to help tailor the various levels of service to operators’ needs, resulting in a unique set of findings that will relate to the specific requirements of an organisation. Download Atlas Copco’s eBook ‘A beginners guide to compressed air system health checks, energy audits and leak detection’ at: https://www.atlascopco.com/en- uk/compressors/customer-offers/health- check-energy-audits-leak-detection?amc_ cid=aff_Audits-ebook_e-book º