Air Power USA is an independent consulting and training firm that helps customers lower their energy costs and get the most from their compressed air system.

They have a long record of success at finding the most efficient way to operate and manage the many components of an air system - including the air compressors, compressor controls, aftercoolers, dryers, filters, supply side piping, air receivers and demand side piping. In addition, they don’t sell equipment which means you will get an unbiased assessment of your compressed air system.

Compressed air systems are extensively used as a source of power for tools and equipment in a variety of industries. Compressed air is an expensive power source and production resource. The Department of Energy and others have reported that most air systems do not operate efficiently and that there are considerable opportunities to save money.

Air Power USA has a well earned reputation of being able to deliver practical and low cost plans that generate thousands of dollars in savings - each year! They can do this for you by reviewing your air system and recommending improvements that cut energy cost, lower maintenance cost and improve the performance of your air system.

You can improve your system and save money with one or more of their primary service options - Level I Audit, Level II Audit and Seminars.

Opportunities to Save

It is a fact that few people understand the true cost of compressed air and the gross magnitude of wasted air and power in most systems. In addition, most managers responsible for air systems are not aware of the low cost involved in identifying and implementing changes that produce significant bottom line pay back.

Air Power USA helps you target and capture, with existing technology, the large savings available which allows you to enjoy all the benefits of a managed compressed air system. The following are the common problems found during most Level I Audits:

• Running excessive pressure.

• Air leaks.

• A lack of air saving devices like venturi nozzles, air curtains, etc..

• Producing high pressure air only to use at low pressure.

• A poor selection of primary air supply.

• A poor selection and application of compressor controls.

• Inappropriate piping for the application.

• A poor selection and application of filters, dryers, connectors and regulators.

• Improper placement of air receiver.

• A poor selection of compressed air to do the job compared to an alternative energy source.

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Level I Audit

The Level I Audit was designed as a comprehensive and economical air survey. You can expect this audit to reduce air demand and power cost from 25 to 50 percent almost immediately. The following are the 4 goals of the Air Power USA Level I Audit:

1. Provide the customer with a quality compressed air system overview at a cost commensurate with the system size, complexity and potential recovery.

2. Generate short and long term plans to establish basic control and management of the air system. Focusing on what is generally needed to pull together all of the interrelated parts of the system and to allow the user to understand the basics of these parts and their relationship.

3. Create a general guide that the user can follow to continue to increase the efficiency of his system.

4. Identify specific programs and/or actions to be implemented with estimated costs and pay back.

The following outline illustrates the parameters of the Level I Audit:

Supply Side

The compressors are evaluated, without disassembly or mechanical work, for the following:

• Suitability for application

• General apparent performance and condition

• Efficiency ratings

• Suitability of unloading controls

• Capability of translating lower air demand into lower power cost

• Potential for modification if required

• Capability for system sequencing

• Installation and support system (cooling water, ventilation, etc.)

A general appraisal is done on alternative types of equipment and controls that may be more preferable and more power efficient.

Air Treatment Equipment

The following components are evaluated, without disassembly or mechanical work:

Aftercoolers

• Effectiveness to reach 100 degrees F for dryer inlet.

• Possible use of auxiliary coolers.

• Installation critique.

Dryers

• Suitability for application/sizing/efficiency/pressure loss/controls.

• Possible modifications to improve performance/efficiency.

Filters

• Suitability for application/efficiency/pressure loss.

Auto Drains

• Are they used and applied correctly.

Supply Side Piping (from compressor to system storage vessel)

• Suitability for application/efficiency/pressure loss.

Air Receiver Placement

• For providing control air, storing dry air and the ability to serve function.

Demand Side

The following areas are evaluated, without disassembly or mechanical work:

• Inspect the distribution piping, particularly the main headers, for efficiency ratings, pressure loss, moisture control and potential for modification.

• Identify the apparent "Load Profile" per shift by total plant and, if possible, by sector.

• Identify the lowest pressure required to operate the production equipment at optimum performance. Identify which sectors limit this.

• Evaluate the potential effectiveness of a demand side control main system and sub systems.

• Look into specific areas of low pressure air distribution problems, moisture and oil carry over problems.

• Identify the electric power cost of compressed air at the facility. Specifically, the cost per CFM and per psig. Translate this to the cost of leaks and otherwise wasted air. Locate, identify, quantify and assign a "cost of loss" or "recovery" to specific examples of "leaks", i.e., open drains, unregulated flows, blow offs, etc.

• Identify an accurate estimate of the total plant leakage by any of several methods.

• Recommend the implementation of a continuing Leak Management Program with training for supervisor and line personnel.

• Identify areas where high pressure air is not being used productively (open blow, low pressure, vacuum generator, etc.).

• Identify potential uses for air saving devices such as venturi nozzles, heat tubes, etc..

• Identify any demand events that might be handled by more effective storage application rather than continual loading and unloading of compressors.

• Identify any areas of potential thermal energy recovery utilizing the generated heat of compression.

• Report all recommendations to save energy including the estimated implementation cost and predicted fiscal recovery.

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Level II Audit

The Level II Audit is a more in depth survey of your air system. It adds the following two key activities not included in the work scope of a Level I Audit:

1. A fully measured and trended evaluation of air flow, pressure and dew point.

2. A complete leak survey of all major compressed air uses.

The first activity includes setting up a full trending analysis of selected measurements and readings over a two-to-three week period. Air Power USA will supply and perform the installation or supervise the installation of transducers, meters, CTDs, etc..

They will leave the recording equipment in place during the trending analysis with the understanding that you accept full responsibility for any lost or damaged equipment. The reporting system will be through telephone line to Air Power USA where the data will be collected, sorted and analyzed to be included in the final report.

The second key activity of a Level II Audit is a comprehensive leak survey. Detailed attention is given to locating, tagging and quantifying leaks.

Air Power USA recommends a phased approach in which the Level I Audit is done first. The Level I Audit will yield a good solid operating plan for follow up programs. These follow up plans may include Level II Audit which is conducted on a more targeted basis.

This approach will identify specific projects, project costs and returns based on actual quotes and probable future projects as the system develops. The premise is that the final overall plan will only emerge as successive projects are implemented on a path toward an overall managed system.

This allows the optimization of the compressed air system to develop and be fine tuned as it grows. It also allows the consultant to work with and help train plant personnel to develop and implement the projects as required.

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Tools Used in Audits

Air Power USA uses standard needle gauges, calibrated gauges, dew point monitors, surface pyrometers, probe type thermometers and orifice flow pressure drop flow meters. In addition, they use some of the following specialized equipment in performing their air system analysis:

• Full set of mechanical orifice plates with proper flow radius. LP07 Multiple Orifice Flow Meter set for 114.69 psig inlet at 60 degrees F with 2% accuracy.

• Infrared remote sensing surface pyrometer - laser directed for reading air system surface temperatures at all critical points.

• Ultraprobe 2000 Ultrasonic Leak Detector with a fixed band sensor and multiple sensitivity level.

Note: Leak detection - air borne ultrasounds such as emitted by pressure/vacuum leaks are read by the Trisonic Scanning module which uses a phased array of three piezoelectric transducers to intensify the signal and detect the smallest leaks. Combined with fixed or adjustable frequency (20 kHz to 100 kHz), the position meter selector, and the versatile sensitivity selection dial and scale - there is no other detector that can more accurately quantify the leak with constant repeatability.

• Sierra Series 640 Heated Probe Type Flow Meter - This electronic compressed air flow meter can enter the air system through a ¼" fitting. These are specifically designed for a single point flow monitoring in the air piping by using Thermal Gas Mass Flow Technology. The heated probe electronically measures the mass flow of the air in the pipe and its velocity in SCFM. This is then compared to pipe diameter and gives an accurate and instantaneous flow reading. The data is available in a 4-20mA output signal or 0-5 volt.

• Kobold Series DSF Digital Pressure Gauge using a piezo-resistance strain gauge element - 14.7 to 5800 psig accurate to + 0.5% of full scale.

• ITT Clamp-On Multimeter - A hand held measuring instrument to measure AC/DC current to 1000 Amps. Also will measure AC/DC Voltage, True Power, Apparent Power, Power Factor and Frequency.

• Amprobe Digimatic Three Phase Amp/Volt Microcomputer Based Display Recorder - Four LED digits recall and display more that 41 days of data from 44 separate functions. Repeatability + 0.1% of full scale.

• Utili Track Monitoring System - Utilizes the OPTO 22 M4RTU stand alone remote telemetry unit that handles host communications and program control while interfacing with digital and analog input signals. Utilizes widely used and accepted commercial software with custom applications delivering real time and historical data.

Air Power USA’s professional, experienced personnel can use these tools with their library of data to find savings opportunities in your compressed air system.

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Success Stories

Case History #1

A brake testing laboratory reduced their air usage 30% after installing a $245 regulator! This was one of the findings from a Level I Audit done by Air Power USA. This one improvement in the air system generated a power cost savings of $12,000 a year plus a maintenance cost savings of $6,000 a year for a total annual savings $18,000!

Case History #2

A foundry asked Air Power USA for a Level I Audit of their air system. Several recommendations were made that solved some low pressure problems and operating problems with their equipment. In addition, some long term recommendations were made to help reduce the daily operating cost and horse power requirements.

They reduced annual operating costs after implementing only some of the ideas from the audit. The plant manager stated that Air Power USA’s insight and recommendations "significantly helped us understand our problems and plan for the future". The improvements generated over $20,000 in annual savings!

Case History #3

A Midwest manufacturing plant was running two 250-hp reciprocating compressors at full load and called Air Power USA for a Level I Audit to find out what size and type of compressor to add to their air system. They learned that another compressor was not needed if they could implement certain improvements.

After the improvements were made, the plant shut off one of its two compressors. Operating on only one unit, the plant suffered no reduction in production. The documented electrical power cost savings in the first year were $80,000. The estimated cost savings for water, maintenance and repairs was $40,000 for a total annual savings of $120,000!

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Air Power USA believes you are known by the company you keep. If you would like to speak to some of their satisfied customers - send an e-mail message to airsavings@compressorwise.com with that request. The following are some of the companies they have worked with over the years (* denotes multiple plants). Click on the <click here for names> button to see the customer names for each category.

• Electric Power Plants 
• Heavy Equipment/Automotive 
• Packaging 
• Food and Food Processing 
• Chemical and Pharmaceutical 
• Pulp and Paper 
• Metals (Mills, Foundries, etc.) 
• Parts Manufacturing 
• Glass/Plastic 
• Refrigeration Products 
• Wire, Cable, Tubing 
• Waste Recovery 
• Building Products 
• Hospitals/Medical Products 
• Refineries 
• Industrial/Consumer Products 
• Communications 
• Printing 
• Gas Transmission 
• Miscellaneous 

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Air Power Seminars

In January 1998, the United States Department of Energy announced The Compressed Air Challenge. This public-private partnership was designed to bring attention to the opportunities for savings and improvements in compressed air systems. One aspect of this program is to develop and deliver information through training seminars.

Air Power USA has been very active in the Compressed Air Challenge Program. They were a charter member of the Compressed Air Efficiency Council and have been chosen as one of Twelve Core Trainers from applicants across the United States.

Air Power USA has developed a "Compressed Air System Technology Seminar". It allows anyone involved with an air system to tap into the knowledge base developed by the Compressed Air Challenge. The objective of the seminar is to instill awareness of the inefficiencies in compressed air systems and to demonstrate how to capture the large energy savings, maintenance savings and productivity improvements.

The Seminar attendees are provided with a practical work book to make it easier for them to make improvements in their plant. The following is the table of contents of this manual:

1. Cost of Compressed Air

2. Compressed Air Supply

3. Compressed Air System Design

4. Basic Use of Storage - Demand Side Control

5. Compressed Air System Review - basic

6. Establish Compressed Air Management Program

7. Running a Leak Survey

8. Miscellaneous

If you would like to speak with Air Power USA about attending a seminar or about having one at your facility, send an e-mail to seminar@compressorwise.com with that message.

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We assume that you are visiting our website because you are interested in learning more about compressors and compressed air systems. 

You can accomplish this objective by taking a moment to sign up for our free newsletter. We use this publication to share specific information that will show you ways to reduce energy costs, solve chronic problems and eliminate maintenance. 

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Pricing - Contact Us

Air Power USA prides itself on the ability to find ways to save you money and improve the overall efficiency of your air system. They can customize a program to help any customer and would be pleased to quote their unique services.

If you would like them to conduct a Level I or Level II Audit, or just want to know more about their successful programs, e-mail airsavings@compressorwise.com to send your request. Please be sure to include your company name, phone number and location in your e-mail message.

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