Audit guide

CALMS is designed for compressed air experts for audits and surveys with detail analysis and actual savings actions identifications.

For your first audit follow First audit checklist and step by step guide.

CALMS will support

  • Supply Audit
    • This consist of just the compressor room/s.
  • Demand Audit
    • This consist of just the production parts of the plant, problem areas
  • Supply & Demand Audit
    • This consist of both the supply and demand parts of the plant.
  • Waste Detection Audit (Leaks, Inappropriate used and Artificial demand)
    • This consist of ultrasonic leak detection to find leaks in a plant.
  • Full Audit

    • This consist of all of the above. Very Thorough look at your plant

      and compressed air system.

Connecting measurements from instrumentation sensors, equipment or PLC control systems with CALMS edge devices:

getting-started-with-cal-edge-0-device.pdf

getting-started-with-cal-edge-8-device.pdf

Auditor hand tools

  • personal safety gears (helmet, googles, ear muffs, shoes, gloves, ..)

  • personal hand tools

  • smart phone with assessment app and photo

  • portable remote logger with amps clamp, pressure, PDP

  • multi-meter and current clamp meter

  • pipe diameter measuring tape

  • laser distance measurement device

  • portable temperature meter or thermal cameras

  • portable pressure transmitter

  • ultrasonic thickness gauge

  • portable ultrasound leak detector

Remote Audit workflow

Audit process diagram

Basic audit - supply side guidelines

  1. Audit planning : CA system details description with PID Schematic: https://app.calms.com/pid/
  • Assessment details: customer name, contact person, address, PO, system description, problems
  1. CALMS Audit basic kit - explorer case prepare and ship with sensors and cables
  2. Customer installs Audit logger and sensors
  • CT Amps for each compressor
  • Pressure Wet and Dry receiver=System pressure
  1. Remote CALMS device Setup with app.calms.com/device & System Setup app.calms.com/setup
  2. Remote Audit tests - start scope live monitoring test app.calms.com/monitoring/inspect
  • each compressor start/stop, load/unload
  • variable speed SP change from min to max power output
  • control system testing (with/without), settings, change SP
  1. Select typical week as slice for analysis and start Audit under Assessment
  2. Create Report under Audit
  3. Open .pdf report in MS Word to edit and add your comments and pictures from CALMS
  4. Select independent expert to perform detail audit and analysis

Full audit - complete system assessment

  • A full assessment of your compressed air system include the complete system –
  • Supply Side equipment (including - installation, control, maintenance, ventilation)
  • Distribution Side pipelines, rings, leaks
  • Demand Side users (pressure, use type, special requirements, leaks, AD, IU)

Standard audit measurements

  • Each air compressor
    • Power / Current – pressure – evaluation of controls and integration with other compressors – comparison of operating condition with equipment design – efficiency during all shifts.
  • Each air dryer, refrigerated , desiccant
    • Power and/or purge flow should be measured.
  • Filter - Dryer - Supply side pressure drop.
    • Did this facility outgrow its infrastructure?
  • System demand side - Flow - Pressure
    • Piping problem by raising the pressure? More pressure requires more energy.
    • POU pressure drop and leaks
    • Any hidden filtration in the ceiling throughout the facility?
    • Is a Leak Study and Inappropriate Use hunt part of this project?
  • Select an independent auditor that has experience with your type of equipment
    • Select audit type
    • Collect data with remote logger to CALMS platform
      • Numbers – Charts – Interpretations - Recommendations
    • Real Action suggestion
    • KPIs
    • Production data.
      • Can you assign costs to a product line?
      • Power costs – Water costs – Heating fuel costs
    • Understand the problems within your existing system.
      • Review maintenance records and costs. Are there maintenance recommendations that have not been acted upon.

Compressor performance service audit

Overview

Calms compressor performance service is based on CALMS analysis and should be performed at least once per year as part of a regular yearly maintenance plan. Service is used to validate CALMS auto analysers in permanent monitoring systems.

Compressor performance service document link

CALMS compressor performance analysis goals:

  • Independent compressor performance verification
  • Manual CALMS auto analyser verification
  • Check performance before and after investment in new equipment
  • Compare history data and characteristic deterioration
  • Service troubleshooting

Compressor performance is measured based on below tolerances :

  • Flow : +- 4%
  • Pressure: +-1%
  • Specific Energy consumption: +-5%
  • No load/ Zero flow power: +-10%

Based on ISO1217 annex C for 15m3/min (500cfm) or more.

Procedure

CALMS compressor performance test must be carried out with compressor operator or service person and expert working live on CALMS Inspect page with scope mode turned ON. The measurement sampling rate is 1 sec. Before starting check and confirm that all measurement equipment was tested and calibrated. The compressor operator must be online connected to CALMS tester (WhatsApp..) . Test duration max 2h.

Instrumentation:

  • Power meter/analyser
  • Pressure sensor
  • Flow sensor
  • CALMS edge gateway

CALMS will use auto analyser tools to collect and calculate all necessary parameters based on measurements. Final compressor performance report will be generated.

Wireless w-mesh modbus sensor connection audit

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