Audit Solutions
Ingersoll-Rand Audit Solutions
IR Air Solutions is helping customers
optimize their systems and even turn off
compressors!
This may sound crazy, but it’s true. In the past
you asked us to build the best-engineered most
reliable, energy-efficient air compressors in the
industry. But in today’s global business climate,
you need more than great equipment to survive
and thrive. Increasing shareholder value for our
customers means we
must go beyond the
components of an air
system and find
solutions to the
operating issues
every customer
faces.
2
The problems
associated with
operating a
modern
compressed air system are
fairly complex. At the same time, many
companies have cut back the internal resources
dedicated to defining and solving those problems.
That’s where IR Audit Solutions can help.
Audit Solutions addresses the total process of
producing compressed air... not just the
compressors. It’s about taking compressed air,
looking at it as your fourth utility, and making
compressed air as stable and consistent as your
other utilities.
Your air system problems require total
solutions. IR Audit Solutions will help
you define system problems, whether
they are in demand, distribution or
supply, and develop cost-efficient
solutions that meet your return on
investment goals.
Benefits of IR Audit Solutions
You can’t manage what you don’t measure.
Knowing what your system is doing is the first
step in reducing costs and improving productivity
• The audit will give you a clear picture of how
your system runs over time. As an option, the
Audit Solution can help you get your own
picture in the future, whether it’s a snapshot,
a movie or real-time data, through a cost
effective management information system.
Reduce Operating Costs
With all audits, the goal is to reduce operating
costs by optimizing your system.
• Solve production and
process problems.
Compressed air
might be “invisible,”
but that doesn’t mean it can’t be
the cause of process problems when
improperly applied.
Pressure
120
PSI to Production
Trend System Performance
110
100
90
80
70
60
Time
• Operating costs can be reduced by up to half
of the current costs.
• Reductions in energy, maintenance, water
and rentals will feed your bottom line.
Power
Power Costs
900
Minimize or Eliminate Future Capital Costs
Increased demand does not always mean adding
new compressors.
• Turning off a compressor or reducing the load
can create a back up machine out of your
existing compressors.
700
500
300
100
Time
• If your system is on the brink of an expansion,
an audit can help you squeeze more out of your
existing system, delaying the need to expand.
If the expansion is large, the audit can help you
“right-size” the components rather than oversize
the equipment “just in case.” This saves money
on both equipment and installation.
Improve Productivity
A thorough audit of your air system can
dramatically improve the productivity of your
compressed air-driven operation
• Stabilize air pressure under all conditions at
all points-of-use. Adding compressors isn’t
the only way to increase pressure at a pointof-use.
• Eliminate moisture, oil or contamination
problems, whether the root cause is the
equipment or the application.
Current vs Proposed Annual Operating Costs
1
2
3
4
Constituent
Current
Electricity
136,162
External Maintenance
62,472
Internal Labor
9,645
Rental Costs
7,648
Totals
$215,927
Project Cost
Simple Payback (months)
Simple ROI
Proposed
71,538
41,648
6,430
—
$119,616
$143,320
17.9
67%
Variance
64,624
20,824
3,215
7,648
$96,311
1. Electrical cost for compressors and dryers based on $0.051/kWh.
2. External labor was provided by the plant.
3. Internal labor is minimal as external contracts are in place.
4. Rental costs averaged over past three years.
These savings can only be achieved with the completion of all action items.
3
The Audit Solution Process
123
4 56 !
+
+
1.
Pre-audit Feasibility Study
+
At minimal to no cost, we conduct
a feasibility study to determine
=
whether an audit can solve your
specific problems. You’ll know
what to expect, and what opportunities there
are, before you commit to spending any
funds.
+
+
The Audit
efficien cy
2.
At the start of the audit, a “kick-off”
meeting with all concerned parties
quality
insures that all needs will be met
and that all involved are in
agreement on the priorities and the goals of
the audit.
After this kick-off meeting, the auditor will
collect information using state-of-the-art data
acquisition equipment to develop an
accurate picture of how your system truly
operates.
As data is developed, the auditor interviews
individuals who can provide further
information on business practices.
At the end of the audit, the auditor holds an
“exit” meeting to summarize and present
findings.
repor t
3.
The Audit Report
The auditor will create a picture of
how the air system operates and
assemble an analysis of ways to
improve system performance.
The final report will contain recommended
improvements, equipment performance
specifications, control configuration and an
implementation schedule. Finally, the report
will contain a solution with a financial
justification that meets your return-oninvestment criteria.
Implementation/Planning
4.
IR Audit Solutions auditors can
direct the efforts of the
implementation team in effecting
the audit recommendations.
Project
Management/Supervise
Implementation
5.
IR Audit Solutions provides
optional project management
and oversight, even full responsibility, for
the implementation. IR project managers
are professional, experienced, and able to
operate and maintain the air system for
you, even to the point of taking ownership
of the assets.
Validation
1 ..
Did the implementation
2.
accomplish all that the audit
promised? IR Audit Solutions
3
can provide optional testing and
6. validation services
covering any
component or the entire air system.
4
Why use Ingersoll-Rand's Audit Services?
Just like you, we believe that results count.
Our auditors are there to help your company
meet its financial business objectives and to
solve your compressed air problems.
Standardized Training, Equipment
and Techniques
Whether your plant is in Shanghai, Stuttgart
or Chicago, the improvement in the
company's financials and in the air system
will be the same. We've
taken the “magic” out of
audits and turned it into a
systemized, repeatable
science. If you're looking to
have solid, consistent, expert
advice for one plant or all
your plants, then put us to the
test.
Knowledge
Passing the final exam for their certification
isn't the end of the road for Ingersoll-Rand
auditors. New technologies, and new
techniques for handling old problems, are
constantly under development, which means
that the auditors enjoy a continuous and
never-ending learning process.
Teamwork
What's better than having one expert on your
team? It's two of course. Our auditors are
routinely cross-audited by a fellow-auditor to
insure that you're getting the most value.
Plus, the size and breadth of the IR Audit
Solutions team means it’s highly likely one of
our auditors has experienced a process and
problems similar to yours.
5
Single Source Responsibility
The entire process is as seamless as you wish
it to be. Our auditors take a “Solutions Neutral”
approach and they can work with your local IR
representative as a team to achieve the goals
of your audit. If you've been in the middle when
a consultant and a contractor point fingers at
each other over something that has gone
wrong, you'll certainly appreciate the IR Audit
Solutions team approach.
All Audits Aren't Created Equal.
There seem to be as many definitions
of the term “air system audit” as
there are auditors out there claiming
to be able to provide a valuable
service to your business. Here are
some suggestions:
• Investigate the audit company’s
equipment, training, techniques
and experience.
• What do they say will be included in their
report?
• Do they analyze your system for opportunity
before they quote the project?
• Who stands behind their work and what are
their resources?
• How many auditors get their compressor
performance training from the engineers that
develop, design and manufacture all types of
compressors all over the world?
• Are they cross-audited?
• Do they provide a plan for moving forward?
Perhaps most important, be sure to find a
company with a worldwide reputation for quality,
reliability, customer service, and engineering
excellence and you’ll see your only choice is IR
Audit Solutions.
More Than Air. Solutions.
Online solutions: www.air.ingersoll-rand.com
KNOW
SSU
R
RE
E
P
C MPRESSED AIR
CHALLENGE
®
Ingersoll-Rand compressors are not designed, intended or approved for breathing air applications. Ingersoll-Rand does not
approve specialized equipment for breathing air applications and assumes no responsibility or liability for compressors used
for breathing air service.
Nothing contained on these pages is intended to extend any warranty or representation, expressed or implied, regarding the
product described herein. Any such warranties or other terms and conditions of sale of products shall be in accordance with
Ingersoll-Rand’s standard terms and conditions of sale for such products, which are available upon request.
Product improvement is a continuing goal at Ingersoll-Rand. Designs and specifications are subject to change without notice
or obligation.
Ingersoll-Rand Company
Air Solutions
P.O. Box 1840
800-D Beaty Street
Davidson, NC 28036
© 2002 Ingersoll-Rand Company
Form 3251
Printed in USA