Compressed Air Audit Services

A compressed air audit conducted by Comairco’s team of certified auditors is the most effective way to maximize your system’s efficiency. Designed to identify energy-saving opportunities, a compressed air energy audit often uncovers simple yet impactful solutions—such as minor piping adjustments, cost-effective compressor control tweaks, or adding storage capacity paired with precision flow controllers. Every compressed air system is unique, and our audits are tailored to address your specific needs for optimal performance.

Often, compressed air audits reveal enough savings to allow compressors to be turned off entirely. These audits can be integrated into existing maintenance contracts, enabling regular re-assessments as your facility, systems, environment, and compressed air requirements evolve over time.

What Is a Compressed Air Audit?

A compressed air audit typically begins with a walk-through evaluation, which serves as the first step in understanding how your system is operating. This initial review can be conducted by facility personnel or, more effectively, by Comairco’s experienced compressed air specialists. During this stage, major inefficiencies such as leaks, improper controls, pressure losses, and unnecessary demand are identified.

While a walk-through does not provide the detailed analysis of a full system assessment or engineering study, it often delivers immediate value. Many facilities achieve energy savings of 25% or more, along with reduced maintenance costs, simply by addressing the issues uncovered during this initial evaluation.

Following the walk-through, Comairco works with your team to determine whether additional analysis is beneficial. For larger or more complex systems—or when critical issues are identified—a more in-depth evaluation may be recommended. These advanced assessments provide detailed insight into system dynamics, including supply and demand relationships, and help uncover root causes of inefficiencies to develop targeted, high-impact improvement strategies.

Comairco tailors each audit level to match your facility’s size, complexity, and operational goals—ensuring you receive the right level of analysis to maximize efficiency, reliability, and long-term cost savings.

Levels of Compressed Air Audits

 

Level 1: Walkthrough Evaluation

A Level 1 Walkthrough Evaluation provides a high-level overview of your compressed air system. It focuses on assessing end uses, system demands, operating pressures, and air quality requirements.

• Distribution Check: Analyzes visible issues like improper pipe sizing, pressure drops, and inadequate storage.
• Supply Evaluation: Reviews compressor types, control strategies, settings, and ineffective condensate management.
• System Mapping: Develops a simplified block diagram to illustrate airflow and plant layout.
• Operational Review: Assesses current facility maintenance practices and operator training levels.
• Final Deliverable: Provides a detailed written report outlining key findings and performance-improving recommendations.

Level 2: System Assessment

A Level 2 System Assessment provides a deeper, data-driven analysis of your system dynamics. It builds upon the walkthrough findings by capturing real-time metrics at critical points.

• Dynamic Data Reading: Collects system readings to isolate pressure fluctuations and airflow demand spikes.
• Advanced Profiling: Develops pressure and demand profiles alongside a detailed system block diagram.
• Inefficiency Pinpointing: Identifies hidden, localized issues to uncover specific energy-saving opportunities.
• Training Audit: Reviews operational procedures to ensure staff can maintain proper system settings.
• Final Deliverable: Provides a comprehensive, product-neutral written report to guide your optimization decisions.

Level 3: Comprehensive System Audit

A Level 3 System Audit delivers our most exhaustive, in-depth evaluation for complex operations. The primary goal is achieving perfect alignment between your supply side and demand side.

• Extended Data Logging: Captures key parameters like pressure, flow, and power consumption over time.
• Root-Cause Analysis: Pinpoints the exact origin of severe system inefficiencies and dynamic performance drops.
• Baseline Establishment: Tracks an accurate performance baseline to visually measure and validate future energy savings.
• Reliability Review: Analyzes deep-level maintenance procedures to secure long-term plant uptime.
• Final Deliverable: Provides a clear roadmap report detailing explicit engineering recommendations and projected ROI results.

How a Compressed Air Audit Works

An effective compressed air audit relies on establishing an accurate system baseline using precise measurement tools. We deploy advanced data loggers and flow meters to capture your facility’s real-time performance over an extended observation period.

Our engineering process follows four structured phases to map and optimize your plant:

Phase 1: Advanced Tool Deployment

We connect data loggers to critical points across your system.

• • Pressure Sensors: Track localized pressure drops and stability fluctuations.
  • Flow Meters: Measure actual air consumption throughout the distribution lines.
  • Power Meters: Record continuous energy draw from your air compressor units.

Phase 2: Real-Time Performance Baselining

Our data logging instruments record live metrics with zero interruption to your daily production. 

• • CFM Tracking: Captures actual airflow utilization spikes across varying shifts.
  • Energy Profiling: Logs real-time electrical power consumption against systemic demand.
  • Pressure Profiling: Documents system pressure behavior during peak and low-use hours.

Phase 3: Demand Pattern Analysis

Our engineering team compiles the logged telemetry data to uncover hidden system behavior.

• • Fluctuation Identification: Isolates operational gaps where air supply mismatches demand.
  • Inefficiency Pinpointing: Tracks exact locations of severe air leaks and artificial demand.
  • Control Evaluation: Assesses if current compressor controls are properly configured.

Phase 4: Control Strategy & Optimization

We use the finalized baseline profile to develop custom control strategies.

• • Targeted Adjustments: Outlines exact recommendations to improve overall plant efficiency.
  • Validation Planning: Sets an accurate performance metric to verify future energy savings.