Manufacturing & Advanced Industrials · Mechanical Systems & Reliability
Compressed Air, Steam & Process Systems Audit
Find the energy and money your utility systems are losing, and fix the biggest items first
Discuss this serviceWhat it is
Compressed Air, Steam & Process Systems Audit
Compressed air, steam, boilers, and process cooling often run continuously and are rarely looked at closely. We measure how these systems actually operate, locate leaks and inefficient control, and recommend improvements ranked by cost, savings, and payback.
- Typical duration
- 2 to 5 weeks
The business problem
Why clients need this
Utility systems are usually built up over many years. Leaks, over-pressurisation, failed steam traps, and poor controls add up to substantial hidden cost and can also hurt production reliability.
- 01
Compressed air leaks and artificial demand waste energy around the clock.
- 02
Failed steam traps, uninsulated lines, and poor boiler tuning increase fuel cost.
- 03
Compressors, boilers, and chillers are often sized or sequenced for conditions that no longer apply.
Our approach
How we deliver it
- 1
System Walk-Through & Data Review
Reviewing equipment, controls, operating schedules, and energy bills to identify the main systems and operating patterns.
- 2
Measurement & Leak Detection
Logging power, flow, and pressure, and using ultrasonic detectors to find compressed air leaks and failed steam traps.
- 3
Efficiency Analysis
Building energy balances, reviewing control strategy and sequencing, and testing the savings from options such as pressure reduction and heat recovery.
- 4
Prioritised Measures
A ranked list of measures with estimated cost, savings, and payback, separating no-cost operational fixes from capital projects.
Data & AI
How technology strengthens this service
Logged data is used to build a load profile for each system, so the savings from each measure are calculated from actual operating patterns and can be verified afterward.
How we use AI across our workTypical deliverables
What you receive
- System audit report with measured baseline
- Leak and steam trap survey with tagged locations and estimated cost of loss
- Energy saving measures with cost, savings, and payback
- Control and sequencing recommendations
Outcomes
What changes for you
- A measured baseline for each major utility system
- Quick wins identified, such as leak repair and pressure set point changes
- A business case for larger projects such as controls, heat recovery, or equipment replacement
Who it is for
- Manufacturing plants
- Food, beverage & chemical processors
- Hospitals & campuses with central plants
- Cold storage facilities
FAQs
Common questions
Does the audit require a shutdown?+
No. Most measurements are made while the plant is running. Some checks, such as a leak survey, are easier during non-production hours.
How much of a compressed air system is typically lost to leaks?+
It varies widely by plant and maintenance practice. We measure it for your system rather than rely on a general figure.
Do you cover boilers and chillers as well?+
Yes. We review boilers, steam distribution, chillers, and cooling towers, and how they are controlled and sequenced.
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Discuss compressed air, steam & process systems audit with our team
Tell us about your site, plant or network. A senior consultant will reply within two business days.