The document provides guidelines for reducing energy costs associated with compressed air systems, as they can contribute significantly to industrial electricity bills. It emphasizes the importance of implementing a system approach to efficiency, including methods for calculating current energy consumption, managing leaks, and involving staff in energy-saving measures. Safety, efficiency, and reliability are highlighted as interconnected priorities in selecting suppliers and operating compressed air systems.

1. Compress
your air costs
Roy Brooks
MSOE IplantE
Technical Development Officer
British Compressed AirSociety

2. ©CrownCopyright
FirstPublished1994
Last Reprint2001
Thisguide updatesandreplacesaprevious
publicationfromthe CarbonTrust,
GPG126 Compressingaircosts.
Publishedinthe UKFebruary2005
© Queen’sPrinterandControllerof HMSO

4. Insist on BCAS- BeCompliant And Safe
ReducingEnergyConsumption
from Compressed Air Usage
Produced by the British Compressed Air Society.
www.bcas.org.uk
www.bcas.org
http://www.bcas.org.uk/article/reducing-
energy-consumption-whitepaper-33.aspx

6. Compressed air can typically account for 10% of an
industrial company’s electricity bill and for some
sectors it can equate to far more.
It therefore makes sense to take targeted action and
make your system more efficient.
Reducing compressed air waste will:
Save energy and costs
Improve reliability and productivity

7. Calculating the System’s Annual Cost.
• Option 1.
On & Off load running time when there is no demand for air.
Then you can estimate the energy consumptionof each
compressor.
• Option 2
A temporary more accurate and cost effective solution is to
install a data logging system over a period of at least seven
days.
• Option 3
To obtain actual electrical consumptionof the compressor(s)
in kilowatt hours (kWh) can be obtained by sub-metering the
compressorhouse.
Take a system approach

8. • A 75kW compressor operating at 7 bar.
• 2 shift pattern – 5 day week - 80 hours per week
• It is on load for 65% of the production time, which is 2,704 hours per year.
• The motor is assumed to be 90% efficient.
• Energy consumption of the compressor whilst on load =
• (75 ÷ 0.9) x 0.65 x 2,704 = 146,466 kWh/year
• There is also energy consumption from the offload running, assuming for a screw compressor
that a part-loaded running draws 25% of the full load power:
• (75 ÷ 0.9) x 0.35 x 0.25 x 1,456 = 10,616 kWh / year
• Total energy consumption of the compressor = 157,082 kWh
• For unit electricity of £0.12/kWh, the annual energy cost is £18,849.
• If production time is 8,320 hours per year, (346 days) this increases to £37,699/year.
A Costed Example

9. Energy efficiency - technology
Establish your current consumption
Purchase energy efficient options & matching
them to your requirements
 https://www.gov.uk/guidance/energy-technology-list
 variable speed devices – if demand is truly
varying
Seek expert advice for major investments
 e.g. heat recovery

10. Avoidable waste - leaks
 Compressed air leaks:
Reduce process reliability
Increase noise levels
Increase energy consumption & costs
 Implement a Leak management programme
 Staff reporting scheme (Use their knowledge)
 Record cause of leaks & Severity
 Prioritise repairs
 Keep doing it!
 Ultrasonic detection

11. Examples of Severe Bad
Practice

12. Energy saving through people
Staff involvement
 Awareness of compressedair energy costs and
environmental impact
 Encourage staff to identify and report waste
 Compressed air safety training
BCAS online course “Working Safely with
compressed air”
http://e-
learning.bcas.org.uk/Course/Category?reference=3bf727eb-
9723-44a1-883c-d21e455ec248

13. Compressed air misuse
 Is a serious health and safetyissue,
 Is Environmentally irresponsible,
 Misuse wastes energy & Increases costs,
 Consider? - low grade duties such as cleaning and cooling
 In some cases a vacuum system can be a safer alternative
to compressedair

14. Energy is a business issue
Business requirements for compressed air systems:
Safety
Reliability / consistency
Productivity
….delivered cost effectively

15. Compressed air safety
Know your responsibilities
Pressure Systems Safety Regulations 2000

16. HSE guidance
http://www.hse.gov.uk/pubns/indg261.pdf

17. Pressure Systems Safety Regulations 2000
http://www.hse.gov.uk/pubns/priced/l122.pdf
http://e-learning.bcas.org.uk/Course/Category?reference=3bf727eb-9723-44a1-883c-d21e455ec248
1998 (PUWER) The Provision and Useof Work Equipment Regulations & HSW Act
The User will provideadequateoperator instructions for the purposeof Health & Safety
Employer of a person who installsPS atW will ensurenothingimpairs safeoperation

18. Choosing your supplier
When choosing your supplier for installation &
maintenance, check for:
 evidence of manufacturer training (Portfolio)
 SKILLcard / Safety Passport
 use of bona-fide products
 safety and compliance knowledge
 adherence to good industry practice
• BCAS Installation Guide
• BCAS Pressure & Leak Testing guide
• BCAS factsheets for EU compliance

19. BCAS products & services
Training Courses
Good industry practice guides
Industry & legislative updates
Interpretation/clarification of regulations
Myth busting
Answers you can't find on Google
www.bcas.org.uk

20. Summary
Take a “system” approach - http://www.bcas.org.uk/media/download.aspx?MediaId=15
Train your people
Safety, energy efficiency and reliability are
related
Measure to manage and prove savings
Choose suppliers that follow good industry
practice
www.bcas.org.uk
training@bcas.org.uk – technical@bcas.org.uk –
Dipcam@bcas.org.uk – Roy@bcas.org.uk