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Case Study # 3

Successful I mplement at ion Energy Conserv at ion Measure


Measure
Effective compressed air leak control program
Equipment
Compressed air system
Industry / Sector
Automobile
Year of Implementation
Continuously followed from 1995
Cost Benefit Analysis
q

Type of Measure: Marginal investment

Annual Energy Savings: 8.64 lakh kWh

Actual cost savings: Rs. 30.00 lakh

Actual cost : Rs. 2 lakh

Payback: One month

Implementation Highlights
Implementation of the measure has resulted in
Annual energy savings of 8.64 lakh kWh.
Reduction in wear and tear of pneumatic tools.
Reduction in maintenance cost .
Increased life of pneumatic tools.
Steady maintenance of pressure in the line.
High awareness among the plant personnel.
Operators are highly motivated in controlling the leakage.
Actual energy savings resulted in very good support from the top management.
Plant has assigned the task of compressed air leakage control as line function.
Incentives such as cash, gifts, certificates were devised by the management for
the best suggestions from the all level of operators with regard to energy
efficiency.

Case Study # 3

Summary

Background

Effective leakage control program of compressed air leakage has


resulted huge energy savings and increased awareness about
compressed air leak control

A leading automobile unit, which produces two wheelers, has seven


large compressors operating with a connected rated output of 7500
cfm. The compressors alone consume about 60 lakh units annually
(i.e., about 12 % of total plant power consumption). The
compressed air usage before the control of leakage was about 6800
cfm, which is estimated by measuring the individual compressor
output and monitoring the loading and unloading time of
compressors.
The compressed air is mainly used in pneumatic tools, instruments,
control valves. Plant had about 12 production shops. Detailed energy
audit was carried out during 1995. During the audit study the
compressed air leakage in individual shop was estimated by
conducting the trials. The estimated leakage in the system was 1400
cfm, which was about 20% total air consumption.
The major leakage is from the joints, hoses, filters, lubricators and
regulators. Detailed survey revealed all specific points of leak
sources.
Plant has taken necessary steps to control the leakage.

Principle

Leaks are a significant source of wasted energy in a compressed air


system, often wasting as much as 20-50% of the compressors
output. Compressed air leaks can also contribute to problems with
system operations, including:
Fluctuating system pressure, which can cause air tools and other
air-operated equipment to function less efficiently, possibly
affecting production
Excess compressor capacity, resulting in higher than necessary
costs decreased service life and increased maintenance of supply
equipment (including the compressor package) due to
unnecessary cycling and increased run time.
Although leaks can occur in any part of the system, the most
common problem areas are: couplings, hoses, tubes, fittings,
pipe joints, quick disconnects, FRLs (filter, regulator, and
lubricator), condensate traps, valves, flanges, packings, thread
sealants, and point of use devices.
Leakage rates are a function of the supply pressure in an
uncontrolled system and increase with higher system pressures.
Leakage rates are also proportional to the square of the orifice
diameter.

Case Study # 3

Suggestions

Fixing leaks once is not enough. Incorporate a leak prevention


program into facilitys operations. It should include identification
and tagging, tracking, repair, verification, and employee
involvement.
Set a reasonable target for cost-effective leak reduction5-10%
of total system flow is typical for industrial facilities.
Once leaks are repaired, re-evaluate your compressed air system
supply. Work with a compressed air systems specialist to adjust
compressor controls.
Also look at alternatives to some
compressed air uses. If a compressor can be turned off, benefits
include cost savings and a system backup

Details of techno-econmics:

Particulars
Annual Total energy savings, kWh

8.64

Annual Cost savings, Rs. lakh

30.00

Cost of Implementation, Rs. lakh

2.00

Simple payback period, Year

Implementa
tion issues

Actual energy savings

1 month

Reduction in leakage of compressed air initially resulted in a little


resistance from operator level in the beginning. After demonstration
of benefits of controlling the leakage and spreading awareness and
introduction of incentive programs, the control program became a
big success.
The plant has taken necessary steps to control the leakage. In
addition, the plant personnel have devised a very effective leak
control program. A special format was developed through which
operators can inform the energy efficiency cell about leakage.
Moreover during lunchtime of the plant, inspection by the energy cell
is made to identify leakage sources.
The leak estimation trial is conducted in the plant periodically from
1995 onwards, and also the cost incurred for leak control is tracked.

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