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Site Energy Assessment

Compressed Air Controls’ Service Technicians can conduct a Site Energy Assessment that includes:

Investigating, through data logging:

  • That the existing compressors are the right size for the site’s air demand. Compressors need to accommodate the pressure and flow requirements of the network. It’s important that your compressors are correctly sized to meet demand on the system. 

  • If there are multiple compressors, we will arrange the ‘run order' to match air supply to demand and make sure machines are operating at their optimum efficiency. For example, base demand could be met with a fixed speed machine and any peaks in demand supplied with a variable speed compressor.

  • The compressor’s supply pressure - for every 1 bar the compressor is set over the required pressure, the system loses about 7% efficiency.

  • That you have the right sized dryer and that it is not faulty- over-drying the air wastes energy and a faulty dryer can cause excessive pressure drops.

  • That the environment does not adversely affect the compressor- air compressors are often installed in service areas with boilers, pumps and chillers. Radiant heat affects air compressor efficiency, generally by 1% for every 3°C the intake air is above outside ambient air temperature.

  • The flow and pressure -we use the equipment specification and profiles of each piece of equipment to estimate the network airflow demand.

  • Your air network considerations and we will look out for symptoms of an unhealthy site. Those symptoms include:

  • Pressure drops in the network. Typical causes include rust, undersized pipes or pipe constrictions and unnecessary deviations, and partly blocked filters.

  • Fluctuating demand can cause large pressure drops across the system.

  • Wrong operating pressure

  • Leakage- if there is leakage, which could cost thousands every year, our Service Technicians can conduct a leak detection survey where we record, tag, quantify and repair the leaks.

  • We can also advise on whether you should consider replacing the existing compressor with an ELGi energy-efficient compressor. Their energy efficiency comes:

    • From using high-efficiency Siemens IE3 and IE4 rated electric motors.

    • ELGi’s EG Series Rotary Screw Air Compressors can be manufactured with in-built VFDs that will vary the motor speed according to the air demand, thereby reducing power consumption.

    • Their Encapsulated (ENCAP/EN) screw air compressors also come with variable frequency drives (VFD) and heat recovery systems.

    • The EN series models also come equipped with the Neuron III Controller that monitors, controls and protects the compressor from failures by shutting down the compressor whenever necessary.

    • ELGi’s standalone VFDs are designed to be retrofitted to different types of compressors, whether they are an ELGi make or not.

We can advise if you need a compressor with a Variable Frequency Drive which can save you energy in three ways:

1. Twenty Five percent energy saving due to the elimination of the unload cycle. 

2. Seven percent due to a reduction in operating pressure.

3. Three percent due to a reduction in leakage and pressure drop.

  • We can also advise if we should install or retrofit ELGi’s unique Heat Recovery system. It is the only one that can recover 96% of wasted heat, other brands’ systems can only recover 70%. This heat can be used to your boiler or to ducts to warm up work areas, saving you money in power and equipment.