AIM: - TO ANALYZE THE TOTAL PNEUMATIC LEAKAGE OF THE PLANT AND

ELIMINATION OF LEAKAGE
THEORY:
Four screw type air compressors are used, two air dryers, and reservoirs

Technical Specifications of the Machines used for Air system

Following air compressors are used
S.No
1
2
3
4

COMPRESSOR
NAME
KPC 1
KPC2
ATLAS COPCO
SULLAIR

CAPACITY

POWER

635 CFM
850 CFM
487 CFM
1000 CFM

110 KW
135 KW
90 KW
150 KW

Before proceeding to the analysis introduction to various components is to be given where the
compressed air is used to perform various operations
Following components are uses compressed air to perform operations:1.
2.
3.
4.

Pneumatic impact wrench

Grinder
Air gun
Actuator

Use of components:1.
2.
3.
4.

Pneumatic impact wrench :- This is used for the bolt tightening operation
Grinder:- This is used to grind the various surfaces
Air gun:- This is used mainly on machines to clean the chip and coolant from the job
Actuator:- This is used for the shifting of the conveyor from one to another

ITRODUCTION TO FRL
FRL STANDS FOR FILTER REGULATOR AND LUBRICATOR
FRL is used for:1. To filter the compressed before being used by component to avoid breakdown due to dust
or any foreign particles.
2. To Regulate the pressure of air as per desired working conditions of the component
3. To lubricate the air being used which will protect the rotating, reciprocating and any
meeting parts from wear and tear and also to protect from rusting.

ANALYSIS SHEETS OF THE PROJECT

CALCULATIONS FOR TOTAL CAPITAL LOSS PER YEAR
Calculations

Leakage(%)=[(T X 100)/(T+t)]
Where: T= on-load time (minutes)
t= off-load time (minutes)

Leakage (CFM free air) =(V X (P1-P2)/T X 14.7) X 1.25

Total system volume, including any downstream secondary air receivers, air mains, and
piping (V, in Cubic feet).

Cost saving = No. of leaks x leakage rate (cfm) x kw/cfm x no.of hrs. x @/kwh

No. of leaks = 532

Leakage rate =0.13 (@80 psig)
KW/CFM = 0.121 KW/CFM (110/635 *0.7)
Working Hrs. =24 hrs. /day
Rupees/KWH = 6.27 Rs/Unit

Cost Savings=532 x 0.13 x 0.121 x 24 x 6.27

= 1259 Rs per day
= 1259 x 25 x 12
= 377700 Rs Annually