IntroductionThe audit staff at Air Perfection Inc. is the most experienced in the industry. It is our goal to provide a comprehensive analysis of each compressed air system and then provide a set of alternative solutions to the client. We then assist in evaluating those alternatives to select that which best suits the clients needs financially and operationally. Clearly defining the existing air demand and electrical power requirements allows us to project the anticipated air demand after completing the recommended modifications and the power which will be required. We believe that to be valid, an audit must record the performance of the system to allow independent verification if necessary. Our audit method includes designing specific solutions to problem compressed air applications in the production areas as well as a complete analysis of the compressed air supply equipment and the overall system efficiency. Defining and estimating the cost of the recommended modifications allows us to provide a preliminary return on investment based for determining the viability of a system upgrade project. We offer services through the implementation of the modifications, system startup, and savings verification.
The science affecting your compressed air system is widely misunderstood and typically no engineering is applied to the design and operation of plant compressed air systems. The result is an inefficient compressed air system that does not adequately support production demand.
Air Perfection's Auditing Service will scientifically show you why your compressed air system is not meeting production demand. And it often has nothing to do with the size of your compressed air system or the type of compressors you are using.
The results of Air Perfection's Auditing Service routinely lead to major increases in plant productivity and profitability, while improving the reliability and maintainability of your compressed air system.
Proving that your compressed air system is inefficient requires simple math. Showing you where and how to improve the efficiency of your system requires the science of compressed air.
Compressed Air is Not FreeIn most plants, compressed air is treated as though it were free. However, as with any other production utility (i.e. steam, chilled water, etc.) there are direct costs and overhead costs associated with the production of compressed air.
So How Much Does it Cost to Operate Just One 100hp Air Compressor?The cost for electrical power to operate this compressor (at an average rate of $.10/kw-hr) is over $68,000 per year. Considering most plants have multiple compressors of various sizes and types, you can see how quickly power costs add up – but electrical power is typically only 60%-70% of the total cost.
The Other 30%-40% of the Cost Includes:
- Maintenance and repair labor for the compressor room equipment, filters, regulators, lubricators, drains, and other air control valves
- Replacement and repair parts required to operate and maintain the equipment
- Rental compressors and dryers
- Cooling water and water treatment costs
- Miscellaneous (insurance, administrative, benefits, house keeping)
Add it all up and the operating costs of just one 100hp compressor are about $75,000 year. In most compressed air systems, we find waste – inappropriate uses of compressed air, abandoned production equipment, excessive leaks and artificial demand. All of these drive up system operating costs and do nothing to increase production efficiency.
Identifying and quantifying these opportunities to improve system efficiency is an important part of Air Perfection's Auditing Service. So that in addition to making system improvements we can justify the costs – typically providing a simple payback in 12-36 months.
Operating Cost Reduction OpportunitiesAir Perfection's Auditing Service is designed to reveal cost reduction opportunities on both the supply side and demand side. However, only 1/3 of the cost reduction opportunities are usually found on the supply side or in the compressor room – and at relatively high capital costs. The real cost reduction opportunities are out in the plant and generally require low capital expenditures.
Operating Costs and SalesThink in terms of product sales and profitability. In order to justify $100,000 in operating costs, you have to have $1,000,000 in sales at a 10% profit. So in this case a 30% reduction in operating costs would translate into a $30,000 increase in bottom-line profits,
Focused on the everyday production cycles of your compressed air system, Air Perfection's Auditing Service does more than simply identify your compressed air related problems – we solve them.
Air Perfection Auditing MethodologyThe analysis of your compressed air system is a critical component of Air Perfection's Auditing Service. A typical analysis requires less than one week of on-site time and consists of the following procedures:
- Determining the actual capability and condition of the individual supply equipment including the compressors, dryers, filters, cooling systems, etc. The relationship of actual efficiency to design efficiency sets the short and long-term priorities for the 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, leaks, artificial demand, and inefficient applications.
- Analyzing and providing solutions to correct applications that are not performing adequately. Correcting applications that require excessive pressure to enhance productivity and provide the flexibility required to operate the supply system at peak efficiency.
- Creating a process flow diagram that depicts the general arrangement of your compressed air system, as well as the supply power and demand volume in all operating 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 will allow us to compare your system to ideal industry costs. Projecting the operating costs for the proposed arrangement will allow us to calculate a return on investment for the recommended improvements to your system.
- Developing a prioritized action plan with capital costs and estimated installation costs for the proposed modifications to your system.
- Providing a complete report including process flow diagrams and/or illustrations to assist in the installation and implementation of the proposed arrangement.
Air Perfection Audit TeamAir Perfection's Auditing Team is comprised of factory trained engineers and field technicians. Statistical data is captured using computerized datalogging equipment.
Air Perfection Auditing ServiceThe science behind an efficient compressed air system starts with the understanding that it has to do one thing… support production. Air Perfection's Auditing Service ensures this with specific recommendations and a written action plan.
In an effort to maximize the efficiency of your current compressed air system and minimize the costs for improvements, we consider a full range of solutions. We scientifically project the impact of our recommendations using measurable and quantifiable numbers.
Air Perfection's Auditing Service is not another quick fix approach to your everyday compressed air problems – it is a serious investment. Our analysis process and resulting recommendations are scientifically proven to optimize your compressed air system and maximize productivity.
So if you’re ready for a practical, scientific approach to compressed air, schedule an audit today and apply the science of compressed air to your future.
Air Perfection's Auditing Service utilizes state-of-the- art steady pressure controllers and automation equipment to optimize the supply-side of your compressed air system.
Alliance Partners:Air Science Engineering, a division of Goodrich is nationally recognized as the top compressed air and vacuum auditing firm in the U.S. Dean Smith is the manager of auditing and system design and has completed more than 400 air system audits and retrofits from food manufacturing to the largest refineries in the country. Dean also holds compressed air system training and workshops for manufacturing facilities while offering private seminars for engineering and maintenance staff for companies of all sizes. Dean recently audited, designed and installed a compressed air system for a large aerospace company in California. This company saved over $ 1,800,000.00 in power cost alone from the cost to operate a standard type compressed air system. Dean's auditing staff are experts on production issues such as, point of use storage, metered recovery and off line storage. For more information, please feel free to e-mail Dean directly at deansmith@airperfectioninc.com.
Biographical Summary of Sr. Audit Staff
- Eight years experience as a consultant in compressed air and gas system analysis; conducting complete audits on over 400 plant air systems in a variety of industries.
- Developed and received patents on compressed air pressure/flow controller.
- Member of the Core Technical Group which was responsible for writing the training materials for the US Department of Energy Compressed Air Challenge.
- Founding member of the Compressed Air Efficiency Council created by industry consultants to promote more efficient use of compressed air in industry.
- Written and published multiple articles on compressed air subjects in national industrial publications.
- General Manager of private compressed air distributorship.
- Five years experience in industrial process equipment analysis; including chemical, pulp and paper, plastics, and environmental equipment.
- Frequent presenter of seminars for the Association of Facilities Engineers, US Department of Energy and others on compressed air topics at national and regional meetings including the Compressed Air Challenge. Training style tends to be low key, interactive approach with questions and problem solving exercises aimed at providing the attendee skills and knowledge which can be applied immediately at their plant.
- Six years experience as a senior analyst in compressed air and gas system analysis.
- Conducting complete audits on over 200 plant air systems in a variety of industries.
- Director and VP of Engineering Thomaston Mills; 24 years in textiles facilities engineering completing several major air system upgrades.
- Senior Engineer in Plant Design and Construction for Westinghouse Corp.
- Registered Professional Engineer in Georgia.
- US Naval Civil Engineer Captain.
- Five years experience as a consultant in compressed air and gas system analysis.
- Conducting audits on over 200 plant air systems in a variety of industries.
- Founding member of the Department of Energy Compressed Air Challenge of the Core Technical Group which was responsible for writing the training materials for the US Department of Energy Compressed Air Challenge.
- Fifteen years experience owning and operating a gas compressor packager and air compressor distributor with more than 60 employees.
- Thirty-one years experience in industrial process equipment analysis; including air and gas compressors and blowers and related cleanup equipment, electrical switchgear, motors and motor controls, water, steam and gas turbines, liquid process pumps, bulk transfer and dust collection systems.
- Presented multiple seminars Department of Energy Compressed Air Challenge, Association of Facilities Engineers, US Department of Energy and others on compressed air topics at both national and regional meetings.
- Active member in the local chapter of the Association of Facilities Engineers (AFE)
- Over twenty years experience in "compressed air and gas" system analysis and design engineering.
- Developed systems hardware and software product lines and trained distribution in audit methods and systems engineering.
- Multiple patent holder for energy efficient control systems for rotary screw compressors.
- Director of Engineering for several major compressor manufacturers.
- Registered Professional Engineer in Wisconsin.
Bill Bullock
Senior Systems Auditor
(410) 442-8096
billbullock@airperfectioninc.com
- Seven years experience in compressed air and gas system analysis; conducting audits on over 200 compressed air systems and designing solutions to problem applications and retrofit requirements to provide a payback for the modifications.
- Manager of Compressed Air Market for a major energy services company performing industrial compressed air system retrofits aimed at reducing energy costs and improving system performance.
- Member of the Department of Energy Compressed Air Challenge Board which was responsible for reviewing the training materials for the US Department of Energy Compressed Air Challenge.
- Nineteen years experience owning and operating a compressor distributorship for major manufacturers in the industry.
- Seven years experience in compressed air and gas system analysis.
- Completed over 150 audits and system retrofits throughout the country.
- Owns and operates a large distributorship with over 40 employee's for a major manufacturer.
- Active member of Association Of Facilities Engineers (AFE)
- Completed Compressed Air Market Transformation Program (CAMP)
- 17 years experience in the hospital engineering field. Current with NFPA 99 compressed air standards.
- Project manager for more than 200 compressed air system retrofits including, bidding with contractors, piping layouts, implementation and start-up procedures, computerized interfacing and overseeing the project.
- Owns and operates a large distributorship with over 40 employee's for a major manufacture.
- Active member of Association For Facilities Engineers (AFE)
Partial National Client List - Refinery and Chemical Industries/ Nation-Wide
- Shell Oil Products Deer Park Refinery Deer Park, TX
- Shell Oil Corp Houston, TX
- Valero Refining Company Shreveport, Louisiana
- Chevron Corporation Richmond, CA
- The Lubrizol Corporation Deer Park, Texas
- Solutia Chemical, Inc Greenwood, South Carolina
- Goodyear Chemical Division Beaumont, TX
- KoSa formerly Celanese Chemical Salisbury NC and Spartanburg SC
- Solutia Chemical, Inc. Pensacola, Florida
- Englehard Corp Chemical Division Elyria, Ohio
Partial Regional Client List - California
- Premier Packaging Dixon, Ca
- Vulcan Forge San Jose, Ca
- Georgia Pacific Gypsum Antioch, Ca
- Mother's Cake & Cookies Oakland, Ca
- American National Can Fairfield, Ca
- California Cedar Products Stockton, Ca
- American National Can Chatsworth, Ca
- Seven-Up Bottling Company Sacramento, Ca
- American National Can Phoenix, Az
- Safeway Bread Richmond, Ca
- United Air Lines S.F. Base
- Abrasive Blasting & Coating Vallejo, Ca
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