Lower pressure can reduce compressor power, leakage and unregulated end-use demand at the same time.
Compressed air audit report generator
Generate a compressed air pre-audit report from compressor room data.
kWhScan helps energy consultants, ESCOs and compressed air solution engineers turn site-readable station data into a structured report covering baseline energy, pressure, controls, equipment selection, leakage, dryer purge and heat recovery.
- Designed for pre-audit screening before a full compressor room audit or retrofit proposal.
- Uses electricity, air volume, pressure, nameplate data, controller readings and optional trend data.
- Separates compressor-side, control-side, distribution-side and heat recovery benefits before totals are shown.
Why this page exists
Compressed air savings are easy to overstate when calculations are isolated.
Leakage, pressure reduction, compressor sequencing, unload loss, centrifugal blow-off and dryer purge can affect the same station baseline. A useful audit report must show which measure owns each saving and which effects overlap.
Fixed-speed screw compressors, VFD units and centrifugal compressors waste energy in different ways.
Purge loss and pressure drop should be separated from compressor replacement or pressure-control measures.
The report should flag pressure class, capacity mismatch or low efficiency only when user data supports it.
Recovered compressor heat can offset another energy source, but should not inflate compressed air electricity savings.
The goal is a reviewable pre-audit report, not a single untraceable total saving number.
Report modules
Five compressed air checks behind the generated report.
The workbench follows a consistent engineering structure so the report can be read by consultants, plant engineers, equipment suppliers and decision makers.
Annual station electricity, air volume or average flow, operating hours, electricity price and station specific energy.
Compressor type, rated power, rated flow, rated pressure, specific power, capacity mix and pressure class mismatch.
Average pressure, pressure band, sequencing, unload hours, VFD low-load operation, IGV position and BOV or blow-off behavior.
Header pressure drop, critical end-use pressure, leakage, dryer purge, drain loss and inappropriate air demand.
Cooling method, useful heat demand, required temperature, operating coincidence and alternative energy value.
Priority measures, next measurements, supplier questions and how to confirm the baseline after implementation.
Data requirements
Start with data a field engineer can usually collect.
The first diagnosis should not require a perfect metering system. Manual fields produce a screening report. A single trend-data import can improve control, pressure and load-distribution diagnosis when available.
- Annual compressor station electricity.
- Annual air volume or average air flow.
- Operating hours and average electricity price.
- Minimum end-use pressure and actual supply pressure.
- Compressor type, rated power, rated flow and rated pressure.
- Run hours, load hours, average load ratio, IGV position or BOV information when available.
- Dryer type, purge ratio if known, pressure drop, leakage observation and heat demand boundary.
- Timestamp, total station power, main air flow and header pressure.
- Aftertreatment inlet and outlet pressure when available.
- Critical end-use pressure when available.
- Per-compressor power, load state, load ratio, IGV or BOV status when available.
Example findings
What the paid compressed air report can unlock.
The full report should show only relevant opportunities found from the user's data. It should not list every possible compressor rule when the evidence is not present.
Finding
Report conclusion
Calculation basis
Pressure level mismatch
Current supply pressure or compressor rated pressure is higher than the end-use requirement. Review pressure reset, low-pressure replacement or impeller/stage retrofit where applicable.
Uses end-use pressure, station pressure, pressure band and pressure-power relationship, with overlap notes for leakage and unregulated demand.
Unloaded running
Fixed-speed units show unloaded hours during the selected period. Review sequencing, trim-machine role or replacement with a better matched unit.
Uses controller run hours and load hours, plus compressor-type no-load power assumptions.
Centrifugal blow-off
IGV and BOV signals suggest operation outside the efficient turndown range. Review capacity mix or compressor control logic.
Uses IGV opening, BOV status or blow-off time, with conservative airflow and power waste assumptions when exact flow is not metered.
Dryer purge and pressure drop
Dryer regeneration and aftertreatment pressure drop are treated as distribution/end-use losses, not duplicated under compressor replacement.
Uses dryer type, purge factor, target purge basis and measured or estimated pressure drop.
Useful heat recovery
Recoverable compressor heat can offset hot water, boiler make-up, space heating or process heat when temperature and operating hours match.
Uses compressor input energy, recoverable heat factor, useful heat demand, operating coincidence and alternative energy price.
Free preview vs full report
Run the diagnosis first. Unlock the full report only when the signal is useful.
The free preview helps decide whether the station deserves a deeper review. The paid unlock is for the complete compressed air report, calculation notes, measure priority and download access.
- Compressed air baseline and saving signal.
- Top opportunity categories.
- Project-level result structure.
- Measure-by-measure compressed air report.
- Calculation trace and assumptions.
- Evidence labels and overlap notes.
- Implementation sequence and M&V notes.
- Download access.
Related resources
Review examples before entering station data.
Use the example pages to judge the report structure, then open the workbench with a compressed-air-focused diagnosis path.
Compressed air audit report example
See the expected report structure for pressure, controls, equipment, leakage, dryer purge and heat recovery.
Compressed air savings calculatorReview the broader calculation page for pressure, unload loss, blow-off, leakage and dryer purge.
Industrial energy audit report generatorUse the multi-system page when compressed air is one part of a larger integrated-energy project.
FAQ
Compressed air report generator questions
Is this only a leakage calculator?
No. Leakage is one module. The report also checks pressure, control, equipment selection, dryer purge, distribution loss and heat recovery.
Can it recommend compressor replacement?
It can flag replacement or retrofit candidates when rated pressure, capacity mix, specific power or operating pattern indicates a likely mismatch. Final selection still requires supplier validation.
Do I need a permanent flow meter?
No. You can start with annual air volume or average flow if available. If flow is not available, the report states the weaker data basis and the next measurement needed.
Can this be used outside the United States?
Yes. International projects can use an international reference basis. Local standards or supplier data can improve the basis when available.
Generate your compressed air pre-audit report.
Start with free screening. Unlock the complete report when the saving signal is worth using in a client or project discussion.