WE KEEP YOUR OPERATION RUNNING - NO DOWNTIME, NO EXCUSES

WE KEEP YOUR OPERATION RUNNING
NO DOWNTIME, NO EXCUSES

Compressed Air Audits & Leak Detection in Texas

Compressed air is the fourth utility, and it rarely gets its own line on the P&L. Leaks, pressure set too high and equipment that does not fit the demand all hide inside the electric bill. Innovative Oil Solutions uses sonar leak detection, data logging and a hands-on walk-through of your system to show where air and money are going, then helps you fix it.

Request a Quote Call 1-830-214-6544

Industrial compressed air system with compressors, dryers and piping reviewed during an air audit

What a Compressed Air Audit Looks At

A useful audit looks at the whole system, not just the compressor that happens to be running loud that day.

  • Supply: compressors, controls, run hours and how the units load, unload and share the work.
  • Air treatment: refrigerated and desiccant dryers, filters and condensate drains, and whether they are sized for the flow and the dew point you need.
  • Distribution: piping, hoses, regulators and connections, where pressure drops and leaks add up.
  • Demand: what your equipment really needs in flow and pressure, by shift and by line.

Request a Quote Call 1-830-214-6544

How the IOS Air Audit Works

1. Walk-through and inventory

We review your compressors, dryers, filters, drains, receivers and piping layout, and ask about the problems your operators see every day.

2. Data logging

We log your system over time to see real flow and pressure behavior, so recommendations are based on your data rather than a guess.

3. Sonar leak detection

Ultrasonic leak detection finds leaks you cannot hear over plant noise. We note where each leak is so it can be repaired.

4. Findings you can act on

You get a clear list of what we found and what to fix first, from quick repairs to longer-term upgrades.

5. Repair and verify

Our technicians can fix leaks, reset pressures, repair drains and service dryers, then check the system again.

6. The right-sized Air Quote

If equipment needs to change, we quote from the audit results. We would rather recommend a smaller, more efficient setup that fits than oversell a machine that is too big.

Request a Quote Call 1-830-214-6544

What We Commonly Find

Every plant is different, but the same issues show up again and again:

  • Leaks at fittings, quick-connects, hoses, regulators and drains that run all day, every day, including nights and weekends.
  • System pressure set higher than the equipment needs. Running at 110 PSI when your tools only need 90 PSI raises energy use by roughly 10%.
  • Compressors short-cycling or running unloaded because the system is not sized or controlled for the real demand.
  • Clogged filters and undersized or corroded piping that cause pressure drop, so the compressor works harder to deliver the same air.
  • Failed or stuck drains that either dump oil-laden condensate or waste compressed air.
  • Wet air from dryers that are overloaded, poorly maintained or the wrong type for the application.

Fixes That Follow an Audit

  • Leak repairs and pressure set points matched to what your equipment needs.
  • Condensate drain repair and routing. On one job, auto drains were dumping oil-laden condensate onto the concrete, and we re-routed them into compliant collection.
  • Dryer and filtration service, including refrigerated and desiccant dryers. We are an authorized Texas distributor for Mikropor dryers.
  • Piping upgrades with Unipipe modular aluminum piping, which uses airtight connections and installs faster than traditional steel.
  • Control and sizing changes, and a look at variable speed drives where demand swings.
  • A review of heat recovery and on-site nitrogen generation where they fit your process.

See more on our Recent Work page.

Who Should Schedule an Audit

An audit pays off most when you are about to buy or replace a compressor, adding a shift or a production line, seeing pressure complaints at the far end of the plant, fighting wet air, or looking at an electric bill that keeps climbing. It is also the right first step for a new preventative maintenance program, because it shows how the system really runs.

We are based in New Braunfels and perform audits for industrial facilities across Texas, including San Antonio, Austin, Houston, Corpus Christi and Dallas–Fort Worth. If something fails along the way, our 24/7 emergency repair team is a phone call away.

Compressed Air Audit FAQs

What is a compressed air audit?

A detailed look at how your plant makes, treats, distributes and uses compressed air. We combine a walk-through, data logging and sonar leak detection to find waste and reliability problems, and recommend fixes in priority order.

How does sonar leak detection work?

Escaping compressed air makes an ultrasonic sound. Our sonar equipment picks up that sound even in a noisy plant, so we can pinpoint leaks you would never hear or see.

Do we have to shut down for an audit?

No. We want to see the system under normal production, so most of the work happens while you run.

Is the audit just a sales pitch for a new compressor?

No. Our Air Quote is built from your audit results. Often the best answer is fixing leaks, lowering pressure or repairing drains and dryers. If new equipment does make sense, we size it to your real demand.

Can you fix what you find?

Yes. Our technicians repair leaks, adjust controls and pressure, service dryers and drains, and can upgrade piping.

Which areas do you serve?

We serve industrial sites across Texas from our New Braunfels headquarters, including San Antonio, Austin, Houston, Corpus Christi and Dallas–Fort Worth.

See the Data Behind Your Air

Request an audit and find out what your compressed air is really costing you.

Request a Quote Call 1-830-214-6544