Issue link: https://www.e-digitaleditions.com/i/1380119
46 / June 2021 powderbulk.com case of an internal positive-pressure event in the kiln. At one cement plant, an in-person audit revealed that these compressed-air supply lines had been switched, which could have led to the camera burning up and costing $10,000 or more to repair. A remote audit alone wouldn't have caught such a mistake. Conclusion A comprehensive compressed-air system audit can help you optimize your system beyond solving current issues or achieving a cost reduction within a couple of business cycles. An independent auditor can lay out long-term solutions in advance for different scenarios that will materially impact both cost and productivity. However, ownership of the process ultimately lies with you. It's your process and your money — keep it that way. It isn't that difficult if you keep an open mind and ask the right questions. PBE Editor's note: Part III of this article, which will be published in July's issue, will describe a post- project- implementation plan to help a plant retain its savings for the long haul. For further reading Find more information on this topic in articles listed under "Compressed air" in the article archive on PBE's website, www.powderbulk.com. Paul Edwards (paul.edwards@loweraircost.com) is founder and president of Compressed Air Consultants (CAC), which he founded as an independent audit firm 18 years ago after starting up the audit business por- tion of a major compressor company. He has a BS in mechanical engineering from the University of Virginia in Charlottesville and is a nationally recognized speaker in several organizations that serve the powder and bulk solids industry. Mauricio Uribe (mauricio.uribe@loweraircost.com) is an auditor at CAC and has been with the auditing team for more than 5 years, primarily conducting international audits. He's the founder of CrowsNest, an independent auditing company established 18 years ago in Santiago, Chile. He has a BS in mechanical engineering. Compressed Air Consultants Charlotte, NC 704-376-2600 www.loweraircost.com outcome. Independent auditors estimated that between 90 and 99 percent of the audits they see by compressor companies include suggestions for new compressors. To be fair, equipment that's getting long in the tooth and utility incentive programs in part drive those numbers. However, when asked what percentage of audits conducted by independent auditors result in recommendations for new compressors — and there's no incentive program or old equipment — the range given was 5 to 20 percent. Finally, some companies are promoting remote audits. This is a shining example of the imprecise use of the word "audit." These services can provide some of the value that a live audit provides, but until there's remote viewing with a high degree of freedom that allows the auditor to explore every nook and cranny of a system, a remote audit will never supplant a live auditor on-site. For example, a kiln at a cement manu- facturing plant has a camera that allows operators to view the inside of the kiln during operation. This cam- era requires one supply of compressed air to create a barrier that protects the camera lens from overheating and a second supply of compressed air that operates a cylinder that retracts the camera to protect it in the MANUFACTURERS OF PROCESS MACHINERY CHEMICALS & PETROCHEMICALS • FOOD PROCESSING • PULP & PAPER PHARMACEUTICALS • PLASTICS AND MORE 128 Market Street • Kenilworth, New Jersey 07033 Phone: 908-259-9292 • Fax: 908-259-9280 www.gocrushers.com ATLANTIC COAST CRUSHERS, INC The Flow-Sentry Crusher is a versatile heavy-duty, in-line machine designed to reduce oversized lumps as they travel through liquid, slurry or powder piping systems. The patented design works well in pressure, gravity or pneumatic applications. Visit us at www.gocrushers.com or contact an ACC representative for additional information on our complete line of standard crushers or to discuss a custom design suitable for your company's unique requirements.