Compressed Air System Optimization

More and more companies are finding that to be competitive in this global economy they need to do more with less. So when budgets are tight and resources scarce, is maintaining your compressed air system a top priority? Most likely not.

Ingersoll Rand's highly trained Compressed Air Assessments team has several solutions to help you. A professional Ingersoll Rand compressed air audit will help uncover the often complex problems associated with operating a modern compressed air system. From performing root cause analysis, to analyzing system efficiency to recommending corrective actions, our audit team evaluates the complete process of producing compressed air...not just the compressors. So whether your goal is to: Improve system reliability, Improve overall system efficiency, Increase your facility's productivity, Extend the life of your system, or Identify, troubleshoot and correct system problems, We can partner with you to create the best solutions that meet your return on investment goals.

Features of Compressed Air System Assessments

Supply-Side Assessments

Focused on the compressors, clean-up equipment and accessories, the supply side audit identifies and quantifies opportunities to reduce energy costs, improve reliability and stability, and achieve appropriate pressure and air quality.

Demand-Side Assessments

Focused inside your factory, we analyze the distribution system, points of use, and key processes to help our customers optimize productivity and efficiently use air in their production evironment.

Full-System Assessments

Fully comprehensive, a Full-System Assessment combines both Supply-Side and Demand-Side scopes of work.

Air System Modeling and Simulation

An electronic model of the compressed air system is generated, from the compressor room through the piping distribution network. Multiple scenarios can be simulated allowing Ingersoll Rand to collaborate with customers for the system design or modification.

Customized for your needs

In a world of cookie-cutter "audits", Ingersoll Rand offers a true consultative team dedicated to system assessments. We listen to what each customer wants to learn and achieve, and tailor each assessment to those customer specifics.

Saving you time and money

The Ingersoll Rand leak assessment features many competitive advantages. Our cutting- edge equipment and certified technicians work quickly and efficiently — even when your facility is up and running at full production. We help you determine which leaks are the most important and cost-effective to repair — and we follow up to make sure the repairs are in good working condition. And since we keep a record of previously identified air leaks, we know exactly what to look for at each visit.

Extensive experience and expertise

Every element of the Ingersoll Rand air leak assessment has been examined to ensure that the best practices are followed. Our certified professionals have vast knowledge of compressed air systems, and our state-of-the-art testing equipment provides accurate results. With more locations throughout North America than our competitors, we execute more leak assessments in a week than most leak survey companies will perform in a year. Plus, we use standard testing processes and compare data across our entire network — leading to greater efficiency, consistency, and value for our customers.

With thousands of successful uses across the globe, IntelliSurvey is a leader for compressor system analysis. Designed to continuously monitor up to four rotary screw or reciprocating compressors, IntelliSurvey's proprietary algorithms take up to a week's worth of data to establish a baseline of current compressor performance. If efficiency improvements can be made, the future savings can be quantified along with the ROI.

Features of IntelliSurvey

Accurate Results

Unlike some competitors who do not measure system pressure, IntelliSurvey combines days of data for both pressure and amperage, to accurately establish a baseline for system performance.

Flexible Capabilities

IntelliSurvey 4.0 is designed to analyze up to four (4) positive displacement air compressors of any manufacturer, model, or vintage.

Justified Investment

IntelliSurvey 4.0 does more than quantify the current state - future state operating costs are calculcated, along with the rate of return for any required investments.

Best in Class Comparison

IntelliSurvey 4.0, the latest version of the IntelliSurvey, even allows the system to be benchmarked against the best-in-class specific power capable for the system's range.

What is Centrifugal Capability Testing?

Capability Testing provides you with assistance in assessing the health of your compressor(s) and budgeting for immediate and future maintenance needs of your system. This testing also ensures that your air compressor is operating at peak capability. During the testing process, data is collected from the compressor through a manual process of surging and throttle surging of the compressor with data loggers. Data such as amps, pressures, temperatures, vibrations are collected at current conditions and then compared to the design of the unit.

Who can benefit from Capability Testing?

• Compressors that have been serviced with non OEM rebuilds and parts are excellent candidates. Centrifugal compressors are not all built the same. When the compressor is manufactured it is built with internal components that are customized for specified application conditions and performance requirements.
• Compressors that have not been internally serviced for over 5-7 years.
• Customers that would like to have their compressor capability verified.

How we execute Capability Testing?

Engineered Product technicians that have been trained to conduct capability testing will collect the data. An experienced applications and systems engineer will then analyze the data to develop the formal report of the compressor evaluated.

What does the testing tell us about the compressor?

Capability Testing will show the health of the unit versus design. This testing will diagnose how far the unit is from its original design and determine the health of the stages mechanically to identify any deterioration.

Why do I need capability testing?

The results of the capability testing will support your justification for the right solutions to ensure your compressor supports your air system to its peak capability. The right solutions may include tested remanufactured airends, performance enhancements, overhauls, PM/PackageCare programs, more extensive audit services, upgraded local and master controls or new equipment sales.

What documentation can I expect from capability testing?

• Natural Surge Test
• Throttle Surge Test
• Design Performance Curve
• Current Performance Curve
• Equipment Inspection Results
• Final Performance Test Report
• Optional – Vibration Analysis and Oil Analysis