Full Plant Audit
A full plant audit incorporating both supply-side and demand-side analysis is the most comprehensive way to analyze an air system. Many “auditors” never leave the compressor room. While this may provide a vague assessment of your system’s current conditions, it only comprises 30% of the system’s improvement potential from both and energy and production standpoint. Zorn takes a systematic approach to every audit which is comprised of the following steps:
- Determining the actual capability and condition of the individual supply equipment including the compressors, dryers, filters, cooling systems, etc. Their actual efficiency compared to design efficiency allows us to determine the viability of all supply equipment.
- Measuring the storage capabilities of the system and its relationship to the changes in air demand that occur in the system. Determining the demand event sizes and comparing them to the relationship of supply power and storage is key to stabilizing the system pressure and often provides major opportunities for efficiency improvement.
- Evaluating the air users in the system including waste, such as leaks, artificial demand, and inefficient applications. Eliminating the waste in the system with engineered alternatives is another area for operating cost reduction.
- Analyzing and providing solutions to correct applications that are not performing acceptably. Correcting applications which require excessive pressure enhances productivity and provides the flexibility required to operate the supply system at peak efficiency.
- Creating a process flow diagram which depicts the general arrangement of the system and the supply power and demand volume in all operating conditions. This will allow the system to be reconfigured to meet all demand conditions efficiently which will require supporting peak loads with storage, protecting critical applications, overcoming any piping or distribution limitations. Creating a proposed arrangement process flow diagram which allows us to analyze the ability of the reconfigured system to meet all demand conditions.
Determining the total operating costs of the system including energy, maintenance, labor, cooling water, etc. Calculating the efficiency of the system in terms of costs vs. air demand supported will allow us to compare your costs and efficiency to industry norms and optimal arrangements. Projecting the operating costs for the proposed arrangement will allow us to calculate a return on investment for the recommended improvements to the system. - Developing a prioritized action plan with capital costs and estimated installation costs for the proposed modifications to the system. This action plan becomes a guide for implementing the recommendations and helps insure that the desired results will be achieved.
- Providing a complete report including existing and proposed process flow diagrams and pressure logger graphs which identify any restrictions in piping. Any necessary piping modifications will be clearly defined in the action plan.