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    Air Audit Report

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    wa PAKCEM PAKCEM Limited Air Audit Report September 07, 2016 AirAudit www.airaudit.com.pk Compressed Air Management AirAudit ‘wwe airalt.com pk Air Audit Report Submitted to the Board Of PAKCEM Limited PAKCEM Limited 7: 492 51 2228763, E-mal: adit@alraudlt.com.pk, Web: htt://www alraudlt.com ple 1 AirAudit wu ara. com pk. PREFACE This Detailed Audit Report includes a summary of findings from assessing data, procedures, interviews held with technical, operation and maintenance team members and by use of Ultrasonic Leak Detector, Flow Meter and Dew point Sensor. The corrective actions on our findings are discussed in this report, which summarizes the auditor's activities, recommendations and possible saving i.e. energy costs, capital and recurring costs through these recommendations. PAKCEM Limited T: +92 81 2228763, E-mal: audit¢@alraudlt.com.pk, Webs: http://www alraudt.com pk 2 AirAudit wu ara. com pk. Table of Contents 1. Executive Summary 08-08 41.4 Context 1.2 Audit Purpose 1.3 Ault Findings 1.4 Audit Methodology 15 Opportunity 16 Approximate Losses 2. Plant Layout 09-13 2.1 Compressor Room Layout 2.1.1 Main Compressor Room 2.1.2 Coal Mill Compressor Room 2.1.3 Cement Mill Compressor Room 22 Factory Layout 2.3 Ideal Compressor Room Layout 3. Compressor Room Observations / Recommendation 14.16 3.1 Inspection of Compressor room 3.1.1 Temperature 3.1.2. Fresh Air Supply 3.1.3. Ventilation 3.1.4 Dustand Fluff in the Supply Air 3.2 Compressor Room Accessories 17-19 3.2.1. Header Position 3.2.2. Presfilter Condition 3.2.3. After-iter condition 3.2.4 Dryer 3.25 Installed Dryers’ Capacities 3.26 Drains 32.7. Receiver Tank 3.2.8 Compressor Load Analysis 3.2.9 Compressor Operational Load Distribution 4, Piping Observations 20 4.1 Piping Network Findings 5. Production Floor Observations a 5.1 Production Floor Findings PAKCEM Limited 7: 492 51 2228763, E-mal: adit@alraudlt.com.pk, Web: htt://www alraudlt.com ple 3 AirAudit wu ara. com pk. 6. Compressed Air Leakages 22-24 6.1 Leakage Schematic Diagram 7. Flow Monitoring 25-26 7.4 Compressed Air Rated Flow 7.2 Compressors Efficiency Test 7.3 Compressed Air Consumption 8. Cost Savings Potential 27-29 9. Conclusion 30 10. Pictorial View of Findi 8s 31-35 10.1 Compressed Air Leakages 10.2 Compressed Air Network Faults 10.3 Compressed Air Flow Monitoring 11, Notes 36 PAKCEM Limited T: +92 81 2228763, E-mal: audit¢@alraudlt.com.pk, Webs: http://www alraudt.com pk 4 AirAudit ‘wi sirau.com ok Audit Procedure ‘The overall audit conducted inthe plant, covers the following areas: * Data collection © Capacities (Compressors, Dryers, Filters and Tanks). © Maintenance Schedule Data, Loading and Off-Loading Hours Compressor installation data Piping Installation data * Inspection Compressor Room (including all accessories). © Production Halls Piping and Piping Structure Cleaning Points Installed Flow Meters Pressure Gauges © Measurements © Flow ‘© Compressor Efficiency Test ©. Plant Consumption Test ‘© Machine Requirement Test Pressure Temperature Dew Point Sensing © Leakage © Detection and Measurement © Compressor Room © Main Lines (© Trenches (If present on Plant) © Production Halls and Maci ‘© Suband connection Lines © Tagging + Layouts © Installed compressor room/rooms © Compressed air installed piping on Plant Layouts © Ideal compressor room Layout © Recommended Layouts * Reporting and Recommendations PAKCEM Limited 7: 492 51 2228763, E-mal: adit@alraudlt.com.pk, Web: htt://www alraudlt.com ple 5 AirAudit ‘wir airoudit.com 9k 1. Executive Summary 11 Context In accordance with Air Audit and Compressed Air Structure Evaluation Plan, AirAudit Private Limited conducted a compressed air audit of PAKCEM Limited from May 3°, 2016 to August 27, 2016. 1.2 Purpose of Air Audit ‘The purpose of the audit isto investigate and highlight; + inefficiencies in the existing compressed air network with recommendations. + Cost /eneray saving options through eliminating wasted ar energy. * Estimated energy saving potential in the existing compressed air installations. 1.3 Audit Findings ‘The detailed compressed air audit was conducted in order to identiy, evaluate and suggest recommendations associated with the existing compressed alr network, The analysis was based upon detection, measuring and examination of compressor room location and installations, distribution piping network analysis and losses in compressed air usage that govern the energy loss, in terms of money. The criteria and methods used in the audit were based on the energy saving at prevalent energy prices. 1.4 Audit Methodology ‘The audit methodology included detection through electronic equipment, data analysis, visual inspection of compressed air system and erviews with the client’s technical staff, related to the compressed air utilty, in conformity with audit guidelines laid out in European, Standard |S0 11011:2013. 1.5. Opportunity (On the basis of AirAudit findings, the estimated cost saving opportunity in the compressed air and major defects of the system are highlighted in this report. 16 ate losses ‘Areas Losses Compressor Room Ventilation PakRs_7,356,960.00 per annum Compressed Air Leakages Pak Rs 16 426,800.00 per annum Off-Load Running of Compressors Pak Rs 1,679,574.17 per annum Compressed airnetwork neficiencies | Paks 418,862.62 per annum Total Pak Rs 25,882, 196.79 per annum PAKCEM Limited 7: 492 51 2228763, E-mal: adit@alraudlt.com.pk, Web: htt://www alraudlt.com ple 6 AirAudit wu ara. com pk. Total Losses Distribution ‘Compressor Room Ventilation ‘Compressed Air Leakages \WOFtLoad Running of Compressors ‘Compressed Air Network Inelfiiences PAKCEM Limited 1: 492 51 2228763, E-mal: audita@alraudlt.com.pk, Web: http://www alraualt.com ple 7 AirAudit wu ara. com pk. Compresses Air Leakages Distribution 1.73% 0.66% PAKCEM Limited ‘Compressor Room wPre-Heater ‘Coat mat Crusher Ml ‘= Raw Mill = Cement mil Packaging Packaging (Slo Towers) mUtIlty Workshop 1: +92 81 2228763, E-mal: audit¢@alraudlt.com.ok, Web: htto://www alraudit.com pe 8 AirAudit 2. Plant Layouts: 2.1. Compressor Room #1 PaO yOSS2UANOD-NIVH PAKCEM Limited T: +92 51 2228763, E-mal: audit @alraudlt.com.pk, Webs: htt://www alraudit.com.ple 9 AirAudit 2.1.2 Compressor Room #2 ee PAKCEM Limited 1,492 51 2228763, €-mal: audité@alraualt.com.pk, Web: http://www alraudit.com.pk 10 irAudit woyskg vonelInUeA PAKCEM Limited 1,492 51 2228763, €-mal: audité@alraualt.com.pk, Web: http://www alraudit.com.pk Fr AirAudit ‘wow airaudi.com pk 2.2. Factory Layout > LNOAWT INV Id Wave Tune ance PAKCEM Limited 1,492 51 2228763, €-mal: audité@alraualt.com.pk, Web: http://www alraudit.com.pk 2 ‘wow airaudi.com pk AirAudi 2.3. Ideal Compressor Room Layout tittt x mm: in | Auto Drain ** Drain outlet water contains oil which should be disposed of according to the environmental regulations, PAKCEM Limited 13 1,492 51 2228763, €-mal: audité@alraualt.com.pk, Web: http://www alraudit.com.pk AirAudit wu ara. com pk. 3. Compressor Room Observations / Recommendations: 3.1. Inspection of Compressor Room ‘The existing installation of your compressors, compressor room and its related accessories were inspected thoroughly and the following inefficiencies were noticed. Finding Effects Recommendations 1) Gross ventilation is not proper in main compressor Ambient temperature rise in Thstall exhaust fans of proper size for cross ventilation (see section 3.1.3) 2) High relative Humidity of Compressor Room. “Moisture in compressed air used in ‘a manufacturing plant causes problems in: 1 Operation of pneumatic systems. 2, Solenoid valves, 3. Airmotors. 4, Adversely affect the process or product being manufactured, 5, Causes rust and increased wear of moving parts in production equipment. Install separate waste water (EERE PAKCEM Limited T: 92.51 2228763, E-mal: audit4@airaudit.com.pk, Web: http://www alraudlit.com.pk 28 AirAudit wu ara. com pk. Total Losses Distribution ‘Compressor Room Ventilation Compressed Air Leakages ‘wOft-Load Running of Compressors ‘Compressed Air Network Ineffiiencies PAKCEM Limited 1-492 51 2228763, €-mal: audit4@alraualt.com.pk, Web: http://www alrauditcom.pk 29 AirAudit wu ara. com pk. 9. Conclusion We have inspected and evaluated PakCem Limited compressed air system in detail and have found it to be inefficient but with some attention, the company may save a very large amount In energy cost. In our present report we have outlined several recommendations to improve the compressed air system and reduce wastage of electrical energy and downtime while improving operational efficiency of your compressor installations. The compressor rooms have major inefficiencies. These are not properly ventilated. All the drains are open in compressor room which increases thee R-H of the room. All these inefficiencies cause the compressors to run excessively which results in consuming more than required energy at reduced output. These inefficiencies also cause the compressor to utilize spare parts excessively, rusting in pipes and moisture propagation causing system failure is also high which causes the production loss. Piping network, at the plant, s made up of steel tube, mostly the type used for water plumbing, and corroded at multiple places (see picture 10.2.3) directly effecting the useful life of filters ‘Manual drains instead of automatic drains are used. Substantial savings are possible by changeover of piping system to aluminum piping specific for compressed air transmission. ia . ‘A Rusted GI Water Pipe Dusting off by workers is done through this expensive used for Compressed Air compressed air ruthlessly from the main compressed air line rather than having a small unit dedicated for it (see picture 10.2.4). In addition to its heavy cost, this is also a safety hazard, (See attached article on “Corrosion in Steel Pipes” placed at the end of this report). A high level of compressed air leakage rate has been detected carefully through our electronic audit equipment, which results in 146.6 kilowatts of electricity wastage and un-necessary wear and tear on the compressors. ‘The department's maximum compressed air consumption and compressor’s efficiency has been monitored through electronic sensor based compressed air flow meter. However, the leakages and piping related losses are advised to be addressed in order to reduce excess running of compressors. ‘There is a large cost saving potential as discussed and evaluated earlier in the report. The Implementation of the recommendations mentioned above is the most essential part of the ‘audit, we expect you to keep them on your highest priority and call us soon for the verification. oft. PAKCEM Limited 1,492 51 2228763, €-mal: audité@alraualt.com.pk, Web: http://www alraudit.com.pk 30 © ' AirAudit 10.Pictorial View of Findings: ee 10.1 Compressed Air Leakages 10.1.1 Leakage at main valve in header. 10.1.2 Leakage and bend in compressed air line. 10.1.3 Leakage and moisture in FRL of compressed airline. PAKCEM Limited 1,492 51 2228763, €-mal: audité@alraualt.com.pk, Web: http://www alraudit.com.pk 31 AirAudit ‘wow airaudi.com pk 10.1.4 Leakage in compressed air lines to bag filters. 10.1.5 Leakage and bends in compressed air line 10.1.6 Leakage and oil in compressed PAKCEM Limited 1,492 51 2228763, €-mal: audité@alraualt.com.pk, Web: http://www alraudit.com.pk 32 AirAudit wu ara. com pk. 10.1.5 Leakage in sub tank joint. 10.2.1 Sharp bend in connection line. 10.2.2 T-Connections in the compressed air piping. PAKCEM Limited 1,492 51 2228763, €-mal: audité@alraualt.com.pk, Web: http://www alraudit.com.pk 33 AirAudit wu ara. com pk. 10.2.3 Corroded compressed air pipe line, 10.2.4 Dusting off with expensive compressed ai. 10.3 Compressed Air Flow Monitoring 10.3.1 Electronic based flow ‘monitor attached in output line of compressor. PAKCEM Limited T: 92.51 2228763, E-mal: audit4@airaudit.com.pk, Web: http://www alraudlit.com.pk 34 AirAudit wu ara. com pk. 10.3.2 Compressed airflow monitoring from Dry airline to Packer. 10.3.4 Compressed air flow ‘monitor attached to compressor L110 ine. PAKCEM Limited 1,492 51 2228763, €-mal: audité@alraualt.com.pk, Web: http://www alraudit.com.pk 35 AirAudit wu ara. com pk. 11.Notes: PAKCEM Limited T: 92.51 2228763, E-mal: audit4@airaudit.com.pk, Web: http://www alraudlit.com.pk 36 Effect of Corrosion in Steel Pipes Its impact on product quality & energy loss by Inntiaz Rastgar ‘Corrosion is one ofthe major causes for degrading performance of steel pipes in compressed air Ree ee ed ae Teen eee eg ted Ce eae nea ee ee ge rg ee ea aren eit) instruments impose plenty ofcst on business. Piting corosionsthe source of pipe leaks. Leakag Cea aes Pere ets eee Eye cease onan Year 0% Most user of tee piping for | — ox ‘their compressed air network id the option for replacement of existing | Yes id system and accesorles ater observing | Years De ‘thefollowingeffetsduetocorasion. | years Es Pipe Appearance Pipes Corrosion stars withthe damage of Pressure Drop Pipe Inner or outer surface coating. When eating on outer surface fades, pipes lok dll anditafectsexternalavdting. aks AS the coating of pipes wor out, corrosion starts due to moisture In compressed al. The gradual iting corrosion ‘continued wth occurrence of aks. Following data about leakage of ‘compressed air through stel pipes i worst ews for compressed air users relying. on ‘ahanized steel piping. ‘About 42% energy saving is possible ‘through leakage contol in compressed air system which aways bor by coresionnstel AirAudit www.airaudit.com.pk Due to high leak rate and corroded Ireguiar inner surface pofe, unacceptable pressure drop occurs. This dop in pressure, Intrety reduce the prof of business. Aust Parties Corrosion generates rust wich i meal in powder form after reaction with ‘onygen. These rust particles flow with compressed arin ste! pipe and badly attack the piping acessories and instruments ie, ‘ters, deers, pressure gauges etc. Poor ‘tration, combined with internally rusted Pipes can bring tramp rust Partclesint the end produc, causing ssf ualty! Wasted Enerey With choked fter by rust and restricted flow through corroded pipes, ‘compressor’ mator will eonsume era power to overcome friction in the flow of compressed. Aircontamination When compressed air passes through rusty pipe, ti contaminated with hydrogen ons and rust particles. This contaminated ait isnot sutablefor_use in ‘many machines and processes. summary Compressed ar loss in stepping through leaks can reach up to almost SOK, after 8-10 years ofnsalation, Therelsaneed to recognize this phenomenon and take carrectve actions. Airs can help denify the health of industlal compressed it systems, on basis of which corrective actions canbeloiated Quality & Economy In COMPRESSED AIR SYSTEM Imtiaz Rastgar Compressed Ai is an Important Cost Factor in Modern Manufacturing Systems Few Senior Managers ask themselves; “How much does it cost to run my compressed air system?” ‘Over the years it has being recognized that this is because many users do not know the operating cost of ‘compressor and compressed air treatment equipment , or how can they can calculate the cost. Also, knowledge of air quality and cost of its production remains a grey area. Proper air quality level required for successful production is an important factor in containing compressed air energy and other operating costs, because higher quality air is more expensive to produce. Tt requires additional air treatment equipment, which increases capital costs as well as energy ‘consumption and maintenance needs. The quality of air produced should be guided by the degree of dryness and filtration needed and by the minimum acceptable contaminant level to the end users. Quality of Compressed Air: High quality compressed air reduces the need for maintenance, increases operating reliability of the pneumatic system, control system and instrumentation and at the same time wear and tear to air-powered machines reduces. Knowing the proper air quality level required for successful production is an important factor in containing compressed air energy and other operating costs. Higher quality air requires additional air treatment equipment, which increases capital costs as well as energy consumption and maintenance Sources of Contaminations in Compressed Air: To understand the intemational standards for compressed air quality, sources of contaminations should be understood, the individual contaminants found within a compressed air system and the problems that contaminants can cause: ‘Sources of contaminations in compressed air are: ‘= Quality of air being drawn in to the compressor + Type and operation of the aircompressor += Compressed air storage devices, air treatment equipments and distribution pipes. needs. The quality of air required should be according to that stated by the manufacturer of air powered machines or requirements of the process. Quality of Air Being Drawn into the Compressor: The effect of intake of the compressor is important. Intake air which is contaminated or hot can impair compressor performance and result in excess energy and maintenance costs. Air compressors draw-in large volumes of air from the surrounding atmosphere containing large numbers of airborne contaminants. Such contaminants build up on compressor components like valves, impeller, rotor etc, Which reduces the capacity ofthe compressor and increases the electrical consumption of the compressor. This increases the operating cost of compressor for the same quantity of air for which it was operating at low operating cost while the intake air was clean. Type and Operation of Compressor: The quality of compressed air is also affected by the selection of the compressor. Compressor itself adds contamination particles in air, lubricator and coolant by wear and tear, resulting in reducing the life of air treatmentequipment, Compressed Air Storage Devices, Air Treatment and Distribution Pipes: The air receiver and system piping are designed to store and distribute the compressed air. AS a ‘consequence they also store the large amounts of contamination drawn into the system. Additionally, piping and air receivers will also cool the moist compressed air forming condensate which causes damage and corrosion. As a result of this corrosion, leakages may occur in the pipes or pipe joints, which are the ‘major cause of wastage of compressed air. Approximately 20-25 % of compressed air is wasted in leaks. Ce te PL Contaminants in Compressed Air: a ae Fusy Pe Atmospheric Dirt F Water Vapors, Condensate Water and + me er od Water Aerosols -- Rust and Pipe Scales Liquid Oil and Oil Aerosols z oil Vapors lo ves Les usta nt Lui i ard OH els Atmospheric Dirt: ‘Atmospheric air in an industrial environment typically contains approximately 140 milion dirt | particles for every cubicmeter of air. Approximately 80% of these particles are less than 2 microns in size and are too small to be captured by the compressor intake filter, therefore passing directly into the compressed air system. Due to these particles efficiency of compressor starts to decrease with time and it starts to consume more electric energy to meet the requirements of air resulting in increased operating cost. Water Vapor, Condensed Water and Water Aerosols: ‘Atmospheric air contains water vapor. The ability of compressed air to hold water vapor is dependent upon its temperature. The higher the temperature, the more water vapor that can be held by the ait. During compression, the air temperature is increased significantly, which allows it to easily retain the incoming moisture. After the compression stage, air is normally cooled to a usable temperature. This reduces the air's ability to retain water vapor, resulting ina proportion of the water vapor being condensed into liquid water which is removed by a condensate drain fitted to the compressor after-cooler. The air leaving the after-cooler is now 100% saturated with water vapor and any further cooling of the air will result in more water vapor condensing into liquid water. Condensation occurs at various stages throughout the system as the air is cooled further by the air receiver, piping and the expansion of air in valves, cylinders, tools and machinery. The condensed water and water aerosols cause corrosion to the storage and distribution system, damage production equipment and the end product. It also reduces production efficiency and increases maintenance costs. Water in any form must be removed to enable the system to run correctly and efficiently. Rust and pipe scale can be found in air receivers and the piping of “wet systems” or systems which were operated “wet” prior to purification equipment being installed. Over time, this contamination breaks away to cause damage or blockage in production equipment which can also contaminate final product and process Liquid Oil and Oil Aerosols: Most air compressors use oll in the compression stage for sealing, lubrication and cooling. During operation, lubricating oil is carried over into the compressed air system as liquid oil and aerosols. This oil mixes with water vapor in the air and is often very acidic, causing damage to the compressed air storage and distribution system, production equipment and final product. |@ Aerosols - Minute droplets of ol suspended in the air stream '@ Wall flow - Oil in liquid form, which creeps along the pipe wall © Vepors or oll mist -Vaporised ol ina cloud form, Oil Vapor: In addition to dirt and water vapor, atmospheric air also contains oil in the form of unburned hydrocarbons, The unburned hydrocarbons drawn into the compressor intake as well as vaporized ol from the compression stage of a lubricated compressor will carry over into a compressed air system where it can cool and condense, causing the same contamination issues as liquid oil. Typical oil vapor concentrations can vary between 0.05 and 0.5mg per cubic meter of ambient air. Compressed Air System Economics: Delivering compressed air to a manufacturing facility is an expensive operation. It requires costly equipment that consumes significant amounts of electricity and needs frequent maintenance. In spite of this, many facilities have no idea how much their compressed air systems cost on an annual basis, or how much money they could save by improving the performance of these systems. ‘The initial cost for a 100-hp compressor is PKR 3,000,000 to PKR 5,000,000 depending on the type of compressor and manufacturer, while annual electricity charges for the same system can reach approximately PKR 5,000,000, Added to this are annual maintenance costs, which can be 10 percent or more of the initial cost of the system. Operating Cost of Compressor: Full Load Operation: Even if compressor is not monitored regularly the calculation of operating cost of compressor is very simple. Following data is required to calculate the operating cost of compressor: 1. Compressor name platerating 2. Annual hours of operation 3. Motor efficiency 4. Costper unit of electricity Annual Electricity | (Motor Rating x Annul Hours of Operation x Electric Cost Cost PKR/Kwh)/Motor Efficiency Motor Rating 55 KW Efficiency 0.9 ‘Annual Operating 7200 Hours Cost Per Kwh 13PKR/ Kwh ‘Annual Electricity Cost | (65x 5760 x 13) 0.9 = 4,576, 000 PKR per Year Based on two shift operation (8+8=16 hours a day) Part Load Operation: If a compressor operates below full load at times and has a good control system, electrical cost will be lower than if the compressor runs at full load during all hours of operation. ‘Annual Electricity | [(Motor Rating x Annul Hours of Operation x Electric Cost Cost PKR/Kwh)/Motor Efficiency x [(percentage time Tuning fully loaded)+ (0.3)x (percentage time unloaded)] Motor Rating KW Efidency 09 ‘Annual Operating | 7200 Hours Cost Per Kwh TSPKR7 Kh PKR Annual Electricity Cost | [(65 x 5760 x 13) /0.9] x [ 080+ (:3)(20)] = 3935,360 Based on two shift operation (8+8=16 hours a day) Inappropriate Use of Compressed Air: Compressed air is not cheapest energy to produce and deliver. Asa result compressed air should not be chosen for applications where another source of energy is more economical. Always use a cost-effective ‘source of power before considering use of compressed air. Many operations can be accomplished by using alternate energy sources. Some examples: ‘© Apply a vacuum system instead of creating a vacuum using compressed air venture methods that flow high pressure air past an orifice. ‘© Use compact air conditioning or fan to cool electric cabinets instead of compressed air vortex tube. Use blowers instead of compressed air to provide cooling, aspirating, agitating, mixing, or to inflate packaging Use brushes, blowers, or vacuum systems instead of compressed air to clean parts or remove debris; Use blowers, electric actuators, or hydraulics instead of compressed air blasts to move parts; Use low pressure air instead of compressed ir for blow guns, air lances, and agitation Use efficient electric motors for tools or actuators (although electric tools can have less precise torque ‘control, shorter ives, and lack the safety of compressed air powered tools). Other improper uses of compressed air are: ©. Unregulated End Uses: ‘A pressure regulator is used to limit maximum end-of-use pressure and is placed in the distribution system just prior to the tool. If a tool operates without a regulator, it uses full system pressure. This results in increased system air demand and energy use, since the tool is using air at this higher pressure. High pressure levels can also increase equipment wear, resulting in higher maintenance costs and shorter tool life. ¢ Abandoned Equipment: Many plants undergo numerous equipment configuration changes over time. In some cases, plant equipment is no longer used. Air flow to this unused equipment should be stopped, preferably as far backin the distribution system as possible without affecting operating equipment. Effective Monitoring Can Reduce Compressed Air System Related Cost: Effective Monitoring instruments can reduce compressed ai related costs Summary: While designing a compressed air system, quality of compressed air and cost to produce and deliver that quality to end user must be kept in mind. An over design system is expensive, because it needs more air treatment equipments. Ths increases capital cost of installation and results in recurring energy cost as well as a certain amount of pressure loss. Main causes of contamination in compressed air are ambient condition of compressor, type of operation of compressor and compressed air storage treatment and distribution pipes. Several types of compressed air contaminations in the compressed air system which includes atmospheric dirt, water vapors, condensate water and water aerosols, rust and pipe oil and scales, liquid oil aerosols have been discussed, Cost ofthe compressor includes operating cost which isin the form of electric bills, maintenance and replacement of equipments. Approximately 20% of aris wasted in the form of leaks which can be reduced to approximately 5 % by ar audit. Air audit should not just look for the leaks in the compressed air system but it should be an air quality audit to check the quality of air being delivered to the particular tool, Other than leakages, there are other inappropriate uses of ‘compressed air which can be very expensive, There are tools and methods which are cheaper for those applications. Quality of air may be different for ever machine and equipment which is given by the manufacturer of the machine. These inappropriate uses of compressed air can be avoided if there is a relationship between ‘compressor user and compressor Supplier Company. Compressor Supplier Company should not be just the supplier of compressor but it should be a compressed air system expert which helps the compressor user ‘company to train the end user staff and give guideline tutorials to the compressor user company. Staff training will help to reduce the inappropriate use of compressed air which will definitely lead to reduction in the cost of compressed air Compressed Air Costs 8 to 10 Times More Than Electricity! Be Careful How You Use It Compressed Air Costs in a Perspective eo Costs over 10 years 4 Maintenance 12% Semana oe Equipment 12% Actean Electricity 76% Regucton "Somand 50% Ten Compressed Air Savings Tips 4. Shut-off Sections and Machines That You Don't Use Asimple manual or motorized valve can save you thousands of euros / dollars. Make sure that air is not through leaks or machines standing in idle mode. Flow meters help to determine to which sections airis flowing. 2. Breath Cool, Freshand Clean Air Acompressor converts 90% of its power into heat. The compressor room heats up, while a compressor uses less energy to compress air. 3° C cooler air, already results in 1% energy saving. 3. Get an Efficient Control System Have insight in your compressed air usage profile, so you can optimize your compressor control system. Let an air audit specialist perform an air audit and make an improvement plan based upon the results. 4. Think About the Required Air Quality Clean compressed air is important for the life span of your compressed air installation. Choose the right quality carefully for specific processes whenever possible, as higher air quality results in higher energy costs. 5. Reduce Off-load Hours Electr ion of a compressor is off-load stage costs 10-30% of the consumption during load hours. At >80% use of the capacity, the off-load control is considered efficient. Choose the right control system. 6. Manage Your Leakage In general there is 20-40% of leakage in a compressed air installation. Implement a leakage management system. Invest in a leak detector. With flow meters you have permanent insight in your leakage level. Consider carrying out an Air Audit. 7. Balance Your System Isyour compressor too big? In some applications the compressor is bigger than necessary, for instance after changes in the production process. The payback time of the investment inasmaller compressor is often short. 8. ReducePressure Every bar pressure reduction gives an instant win of 7% on your energy consumption. Invest in pressure regulators per production area, use better vessels and reduce pressure swings in your network. 9. Think of Alternative Uses Compressed air is 8 times more expensive than electric power. However compressed air often is used simply because it is present. The VP Flow Scope offers insight in the usage and helps you to select the right solution 10. Choose Right Pipe Sizing Aproper pipe sizing system is crucial to limit your pressure drop. Too small piping creates pressure loss. Consider using seamless plastic or aluminum pipes instead of seam welded steel pipes. This will improve airflow, reduce pressure loss. www.airaudit.com.pk a: a GTS 12 psi far | Kk te LoL nS2z 40 psi

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