Search

Compressed Air Audit Services in NC, SC & VA

High energy costs, pressure problems, air leaks, moisture, and inefficient compressor performance can all affect the reliability and efficiency of your compressed air system.

Lewis Systems provides comprehensive compressed air audits for industrial facilities throughout North Carolina, South Carolina, and Virginia. Using measured system data and detailed analysis, our team identifies air loss, inefficiencies, and performance issues and provides actionable recommendations to help reduce operating costs, improve reliability, and optimize compressed air system performance.

Types of Compressed Air Audits

Compressed air audits help identify the specific issues affecting your system, from hidden air leaks and inefficient equipment to excessive air use and high energy costs. Each audit focuses on a different area of system performance, helping you understand where improvements can have the greatest impact.

Find Where Compressed Air Is Being Lost

Air Leak Audit

Identify leaks throughout your compressed air system that may be wasting energy, reducing available capacity, and increasing operating costs.

Improve Your Compressed Air System Performance

Supply-Side Air Audit

Evaluate compressors, dryers, filters, controls, pressure, and other supply-side equipment to identify issues affecting efficiency, reliability, and overall system performance.

Reduce Unnecessary Compressed Air Use

Demand-Side Air Audit

Evaluate how and where compressed air is being used throughout your facility to uncover inappropriate uses, excessive demand, and opportunities to reduce consumption.

Find Opportunities to Lower Energy Costs

Energy & Efficiency Audit

Analyze system operation and energy use to identify inefficiencies and opportunities to reduce compressed air operating costs. 

Request an Air Audit

Benefits of a Compressed Air Audit

A compressed air audit gives your team the data needed to better understand system performance, energy use, and operating costs. Instead of guessing where problems are occurring, an audit helps identify where compressed air and energy are being wasted and which improvements could have the greatest impact.

For facilities throughout North Carolina, South Carolina, and Virginia, a compressed air audit can help:

  • Reduce compressed air and energy costs
  • Improve pressure stability and system reliability
  • Recover available system capacity
  • Improve compressor efficiency
  • Identify moisture and air-quality concerns
  • Reduce unnecessary compressor runtime
  • Prioritize repairs and system improvements
  • Plan future upgrades using measured system data

The result is a clear, system-specific plan to help improve efficiency, reliability, and overall compressed air system performance.

What Do You Receive From a Compressed Air Audit?

Following the audit, you receive a detailed report that turns system findings into actionable recommendations for improving your compressed air system.

Depending on the scope of the audit, your report may include:

  • Executive summary and key findings
  • Compressed air usage and operating-cost analysis
  • Engineering analysis, graphs, and calculations
  • Compressor efficiency compared with manufacturer specifications
  • Estimated air leak losses
  • Current versus proposed operating costs
  • Prioritized recommendations
  • Estimated equipment and installation costs
  • Estimated annual savings
  • Updated compressor layout or system sketch

Recommendations can be prioritized based on your facility’s needs, helping your team determine which improvements should be addressed first and which can be planned for the future.

Find and Quantify Compressed Air Leaks

Compressed air leaks increase energy use, reduce available capacity, and keep compressors running harder than necessary.

N2O2 uses ultrasonic leak detection to locate hidden leaks and documents each one with a photograph, estimated leak rate, and annual cost.

This helps your team:

  • See where compressed air is being lost
  • Prioritize the most costly leaks
  • Recover system capacity
  • Reduce unnecessary compressor runtime

How Lewis Systems and N2O2 Work Together

Lewis Systems serves as your local compressed air partner while N2O2 provides the specialized engineering analysis behind the audit. Together, the process gives your facility detailed system data along with local support for evaluating and implementing the recommended improvements.

Start With Lewis

Tell our team what you are seeing in your compressed air system and what you want to better understand. Whether you’re dealing with rising energy costs, pressure problems, moisture, leaks, or capacity concerns, we’ll help determine the appropriate audit scope.

N2O2 Performs the Audit

N2O2 engineers collect and analyze system data under normal operating conditions and develop detailed findings and recommendations.

Review the Results

The audit report identifies the conditions affecting system performance, estimated costs and opportunities for improvement. 

Plan the Next Steps

N2O2 develops proposed improvements through Lewis, and our team works with you to review the recommendations and determine the appropriate next steps for your compressed air system.

Local Support Beyond the Audit

 

Identifying opportunities for improvement is only the first step. Lewis Systems provides compressed air equipment, service, and technical support to help facilities address issues uncovered during an air audit.

Depending on your system needs, Lewis Systems can support:

  • Industrial air compressor service and repair
  • Preventive maintenance
  • Compressor troubleshooting and system optimization
  • Air dryers and filtration
  • Compressed air equipment replacement and upgrades
  • Energy-saving solutions
  • Compressed air system support
  • Equipment installation and ongoing service

Our team helps turn audit findings into practical system improvements that can increase reliability, improve efficiency, reduce operating costs, and support long-term compressed air performance.

Get a Clearer Picture of Your Compressed Air System

Whether you’re addressing high operating costs, pressure problems, air leaks, moisture, or capacity concerns, Lewis can help coordinate a compressed air audit based on your facility, equipment, and actual operating conditions.

Request a Compressed Air Audit

Frequently Asked Questions

What is a compressed air audit?

A compressed air audit evaluates how compressed air is generated, treated, distributed, and used throughout your facility. System data is analyzed to identify air leaks, pressure issues, inefficiencies, capacity concerns, and opportunities to improve overall system performance.

How do I know if my facility needs a compressed air audit?

Rising energy costs, inconsistent pressure, frequent compressor cycling, suspected air leaks, moisture issues, insufficient capacity, or declining system performance can all be signs that your compressed air system should be evaluated. An audit can also provide valuable information before purchasing new equipment or making major system changes.

Can a compressed air audit help reduce energy costs?

Yes. A compressed air audit can identify sources of unnecessary energy use, including air leaks, excessive system pressure, inefficient compressor operation, artificial demand, and other system inefficiencies. Addressing these issues can help reduce energy consumption and operating costs.

Can an air audit determine if I need another compressor?

Yes. An audit evaluates actual compressed air demand and available system capacity. This can help determine whether additional compressor capacity is necessary or whether existing capacity can be recovered through leak repair, pressure optimization, improved controls, additional storage, or other system improvements.

What is included in a compressed air audit report?

Depending on the scope of the audit, your report may include system performance data, compressed air usage, operating-cost analysis, compressor efficiency information, estimated air leak losses, graphs and calculations, prioritized recommendations, projected improvement costs, and estimated annual savings.

What happens after a compressed air audit?

After the audit, Lewis Systems can help review the findings and determine the appropriate next steps for your compressed air system. Depending on your facility’s needs, this may include repairs, preventive maintenance, leak correction, system optimization, equipment upgrades, or other improvements designed to increase efficiency and reliability.

What areas does Lewis Systems serve?

Lewis Systems supports industrial and manufacturing facilities throughout North Carolina, South Carolina, and Virginia with compressed air equipment, service, maintenance, and system support.

Testimonial

In the fall of 2008, Lewis Systems & Service was contracted by Graham-White to perform a supply side compressed air audit at our main manufacturing facility in Salem, VA. The audit was performed on two plant systems. The first system provides low pressure compressed air for general use in the manufacturing processes. The second system provides higher pressure air used in testing Graham-White’s products.

During the week-long audit Lewis Systems recorded flow, pressure and amps for each compressor at 12 second intervals. After the audit was complete, Graham-White was provided with a complete study showing all of the captured data along with recommendations for improvements.

In the case of the test air system, one of the recommendations was to simply designate a smaller, existing compressor as the primary unit and utilize another compressor to automatically trim the load based on demand. This small change promised to save Graham-White approximately $10k per year in energy costs.

The recommendation with the greatest money saving potential was to purchase and install a Gardner-Denver model VS80 variable speed rotary screw compressor. The variable speed machine adjusts its speed to the demand for air based on downstream system pressure. The projected energy savings was around $17k per year. After the machine was purchased and installed a justification audit was performed, the actual savings was over $21k.

Ben Grisso
Graham-White Manufacturing