Validate specific power
Calculate total station input kW per delivered flow at matching timestamps and operating conditions. Keep the chosen flow basis and included auxiliaries explicit.
Compressed air audit checklist
Measure pressure, control, leakage and end use before adding the savings.
This field checklist builds a reviewable compressed-air baseline and prevents pressure, leakage, controls and equipment measures from claiming the same energy twice. Use at least one representative production cycle; use longer trends where load varies by shift or product.
Other formats: print-ready PDFCSV data
Field data checklist
Minimum readings for a credible screen.
Nameplate data alone cannot establish station performance. Record timestamps, units, meter location and operating state with every reading.
| Field | Collect | Preferred resolution | Decision use |
|---|---|---|---|
| Station electricity | Compressor, dryer and auxiliary kW/kWh; meter boundary | 1-minute trend for 7 days; utility bills for 12 months | Baseline, demand and specific power |
| Delivered air | Header flow with meter range, location and pressure basis | Aligned 1-minute trend | Station specific power and load profile |
| Pressure | Compressor discharge, main header and critical end-use pressure | Aligned 1-minute trend; spot checks at remote points | Pressure band, drop and minimum requirement |
| Compressor state | Loaded, unloaded, VSD speed, blow-off, starts and sequencer state | 1-minute or controller event log | Unload loss, staging and control stability |
| Equipment record | Rated power/flow, test sheet, cooling type, service hours | Current record plus latest service test | Capacity check and data validation |
| Leak survey | Tag, location, estimated/measured flow, repair status and pressure | One full survey; repeat after repair | Leak load without double counting pressure effects |
| Air treatment | Dryer type, dew point, purge/control mode, drains and pressure drop | Trend or timed test by operating mode | Purge, drain and pressure-loss opportunity |
| End uses | Required pressure, duty cycle, regulator setting and inappropriate uses | Representative cycle by major user | Demand reduction and pressure boundary |
| Production context | Shift, line state, output, shutdown and weekend schedule | Aligned with energy trends | Normalize baseline and separate production change |
Audit sequence
Calculate the system in this order.
Establish minimum pressure
Measure the critical end use and distribution drop before changing the setpoint. A pressure target based only on the compressor room is incomplete.
Quantify control loss
Use measured loaded/unloaded or blow-off power and duration. Do not replace controller evidence with a generic percentage.
Assign leakage and end-use demand
Tag each load owner and keep leak-flow estimates at the measured pressure. Separate repairable leaks from intentional process demand.
Check treatment and heat recovery
Record dryer purge, pressure loss and condensate drains. Report useful recovered heat as displaced thermal utility, not extra compressor-electricity saving.
Overlap control
Do not add dependent savings against the original baseline.
| Measures | Overlap mechanism | Aggregation rule |
|---|---|---|
| Pressure reduction + leak repair | Lower pressure also lowers unregulated leak flow | Recalculate residual leakage after the pressure change, or assign the pressure effect once |
| Pressure reduction + end-use regulation | Both reduce unregulated demand | Model regulated and unregulated users separately |
| Sequencing + compressor replacement | Replacement changes which machines and control states remain | Simulate the final equipment set and sequence, not two independent percentages |
| Leak repair + controls | Lower demand changes unload and VSD operating hours | Apply the repaired load profile before calculating control savings |
| Heat recovery + compressor kWh | Recovered heat displaces fuel/heat; it may not reduce compressor input | Report electric and thermal effects separately |
M&V minimum
Repeat the same boundary before and after the change.
Trend station kW, delivered flow, header pressure, compressor states and production context. Record setpoint and equipment changes. Compare matched operating periods or normalize for production and hours; keep safety and critical-pressure constraints unchanged.
Sources and responsibility
Use this as a pre-audit tool, not an investment guarantee.
Use the field data in a reviewable diagnosis.
Representative examples explain the method. Replace all sample values with site-specific plant data before an investment decision.