Energy conservation in Air Compressor

Reducing Compressed air leakages in the plant and thereby reducing running hours of air compressors on load

Description of Existing system and its operation- Leakage test was conducted and leakage percent was found to be around 35%

Description of Proposed system and its operation-
In a good air system, the permissible air leakage is 10% only and hence around 25% leakages need to be plugged.
 

Energy saving calculations:     Average Unload time 9 Seconds Average load time 15 Seconds Percent leakage= Average load time/(Average load time + Avg. Unload time) x 100     0.375   Percent leakage= 37.50%     This leakage is high and should be brought down.   Avg. Power consumption of bigger air compressor 58.5 on load and 39.1 on un-load for screw comp no-4   Air leakages which should be plugged 27.50%   Average power which can be saved per annum by plugging leakages for 24 hrs of its use per day. Assuming comp runs on load is around 60% of total time 28041 Units       Annual Energy saving potential 28041 units   Annual cost saving @ Rs. 8/Unit 224326   Annual cost Saving in INR INR 224326/-   Investment INR 5000/-   Simple payback period 0.02 Year