1. Compressed Air Repair Implementation
Kevin Whitehead
Sr. Technician
TVA (retired)
Kenley Allen
Sr. Utility Analyst
Yates Services at Nissan-Decherd
Calculating the Financial Opportunity of Fixing Leaks
July 17, 2013 – Industrial Energy Efficiency Summit

2. Presenter Background
• Personal Info
–Retired after 30+ years working in TVA’s
energy conservation programs
–Certified Energy Manager (CEM)
–Certified Level 2 infrared thermography
–Certified Level 2 airborne ultrasound
detection

3. The 4 Major Utilities in an Industry
•Electricity
•Natural Gas
•Water
•Compressed Air

4. I Always Thought That…
Compressed Air is FREE !

5. Reality
NOT !!!

6. Issues with Compressed Air
• Not Enough
• Not Enough Pressure
• Contaminates in the Lines
• Misuse of Compressed Air
• Wrong Compressor(s) for the Job
• Leaks

7. LEAKS
• Can Be 25%-55% of an Industries’
Cost to Generate Compressed Air
• Fixing Leaks Can Justify Turning Off
Compressors

8. Things to Know When Preforming a Leak Survey
A-How many compressors are in operation?
B-What kind of compressor(s) are at the facility? (rotary, centrifugal,
reciprocating)
C-Is the name-plate data and operating specification readily available?
D-What are the loading/unloading characteristics of the system?
E-What are the hours of operation of the facility/compressor system?
F-What is the cost of electricity? (energy charge & demand charge)
G-If multiple compressors are used, are they located together or apart?
H-If there are multiple compressors, are there multiple piping systems?
I-What is/are the delivery pressure(s) to the equipment?
J-How many and what kind of dryers are there?
K-How many and what size are the storage tanks?

9. Plant Layout
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10. Searching For Leaks

11. Tagging the Leak

12. Oh Boy!!
YOU’VE FOUND A LEAK!
IS IT WORTH REPAIRING?

13. Old Fashion Way of Calculating Cost
Another way to calculate cost is
by using the following formula:
(cfm)($/kWh)(.207)(hours of
operation per year)

14. Spreadsheet Method
COMPANYNAME 0 Leak Total=> 835 438,744 54,843$ 1,513,667 8,846$
Type
Leak# Column# Equip. # LeakDescription H F R Other
Pressure
(PSI)
Sensitivity
Level
Flow Rate
(CFM)
Annual
Vol. (kcf)
Annual
Savings ($)
Energy
(kWh/yr.)
Repair
Date
Sensitivity
Level
Repaired
Savings ($)
1 3.4 1,769 221$ 6,103 ####### 221$
2 3.4 1,769 221$ 6,103 -$
3 3.4 1,769 221$ 6,103 -$
4 3.4 1,769 221$ 6,103 -$
5 3.4 1,769 221$ 6,103 -$
6 3.4 1,769 221$ 6,103 ####### 221$
7 3.4 1,769 221$ 6,103 ####### 221$
8 3.4 1,769 221$ 6,103 -$
9 3.4 1,769 221$ 6,103 -$
10 3.4 1,769 221$ 6,103 -$
11 3.4 1,769 221$ 6,103 -$
12 3.4 1,769 221$ 6,103 -$
13 3.4 1,769 221$ 6,103 -$
14 3.4 1,769 221$ 6,103 -$
15 3.4 1,769 221$ 6,103 -$
16 3.4 1,769 221$ 6,103 -$
17 3.4 1,769 221$ 6,103 -$
18 3.4 1,769 221$ 6,103 -$
19 3.4 1,769 221$ 6,103 -$

15. Video

17. A New Approach!

18. Making Air Leaks Visual

19. Non Production Base-Lining

20. Air Leak Pressure Gauge
Two variables must be known to estimate the CFM of
compressed air leakage.
1) Pressure within the line near the leak while leaking in
conjunction with…
2) the decibel reading through proper use of the Ultrasonic
leak detector.
When there were no existing pressure gauges installed
near the leak a technician would have to estimate (guess)
the flow pressure.

21. In-Line Pressure Gauge
Using the in-line air gauge
tool helps increase the
accuracy of calculating
CFM of leaking air
If the line air pressure is unknown, insert the gauge, take a flow
pressure reading before making the repair…
Then again after making the repair for a static pressure reading.

22. In-Line Pressure Gauge Example
EXAMPLE: If the Ultrasonic gun indicated 99dB
and an estimation of 50# flow pressure would
equal 9.6 CFM of leakage.
Using the gauge indicates an actual flow
pressure of 75# then leak is actually 10.0
CFM (a 4% improvement in CFM estimation
accuracy)

23. • Quantify the Loss: First analysis of Kevin’s
random Audit

26. Decherd Air Compressor Run Time History
7 ALL Compressor’s
kWh From Air Leak Repairs