1) The document discusses monitoring and measuring key parameters in compressed air systems to identify savings opportunities, such as energy efficiency, leakage levels, and compressor diagnostics. 2) Leakage management can provide the largest potential savings at 42% of total savings, followed by system optimization at 26%. Leakages as small as 1.5mm in diameter can cost thousands per year. 3) Proper monitoring and measuring of reliability, dew point, flow, pressure, temperature, and energy use allows compressed air systems to move from an uninformed "guessing" approach to an understanding of savings opportunities and managing the optimization process.

1. Monitoring & Measuring
From guessing to understanding
Energy saving services in compressed air systems

2. Source: CAS, In the EU
System design
12%
Motor control
10%
Heat recovery
10%
Optimisation
26%
Where is the savings potential in a compressed air system?
Leakage management
42%
Training ?

3. Leakage Ø / mm Volume /m3 per year Cost per year
0,5 7,709 INR 9,375
1 38,500 INR 48,000
1,5 65,700 INR 80,625
2 136,600 INR 1.7 L
3 307,500 Inr 3.82 L
4 546,600 INR 6.82 L
What do leakages cost ? Below is only for ONE LEAK !
Based on 7 barg, INR 1.5/m3, 365/24/7

4. Return on investment : Sensible Investments reap value
0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
< 6
months
1 - 2
Years
2 Years 2 - 3
Years 10 Years
Leakage Management
Optimisation
Motor control
Heat Recovery
System design
% of Potential

5.  Limited measuring
 Cost not established
 Sporadic leakage detection
 No targets set
 Energy efficiency not
monitored
 Optimisation not initiated
 No measuring
 Cost not established
 No leakage management
 No targets set
 Air quality not established
 Measuring i real time of all
critical parameters.
 Established cost per cbm
 Leakage management on
monitored basis
 Optimisation program
 Targets set and monitored
 System for handling of
deviating data
 CO2 accounted for
 Compressed air cost
allocated on product level
 < 5% leakage rate
 Compressor configuration
verified
 Energy efficiency verified
 Purchasing directives
issued for machine and
component suppliers
Cost saving process
Possible cost reduction 30-50%
Level 1
Level 2
Level 3
Level 4

6. Energy saving process
Reduction of compressed air
consumption and CO2 emissions
Compressed
Air training
System
analysis
Leakage
detection
Product
Identification
Monitoring
Repair Optimisation
Filter changes
Monitored
agreement

7. MONITORING & MEASURING OF COMPRESSED AIR SYSTEMS
Reliability
Dewpoint
Flow
Pressure
Temperature
kW
Energy efficiency
How do you manage the process?

8. Key areas to monitor in a compressed air system
Reliability – Critical levels
• Flow
• Pressure
• Dewpoint
Identify the savings potential
• Energy efficiency
• Leakage levels
• Compressor diagnostics
Verification of actions taken
• Optimisation of applications
• Changes in pressure
• Optimal interval of leakage detection
• New compressors
• Energy audits or complying to – ISO 50001

9. Survey and Repair provides
the answer to the real cost
of leakages
See example in next slide

10. Total consumption of power (approx) 43.5+42+9.2+9.2=103.9 KW
Hours/Per Day 22 Hours
KwHr consumed per day 2285.8
Unit cost 6 Rs/Kw.hr
Calculated Cost per year 4937328 Rs
Leakage 39 percent
Saving s potential 1925557.9 Rs (approx 20 lakh Rs/year)
SAVINGS POTENTIAL:
M/S Kandui Energy Cost Calculation: (As per Data)
REMARK:
If we will arrest all the leaks we can save approx 20 lakh Rs per year.

11. Temporary & Mobile measuring

12. Ethernet Modbus Pressure USBFlow Temperature
Till Din PC
via Ethernet
Display terminal - Permanent monitoring

13. 1,3 M3/min
125 kW
29 M3/min
14,5 M3/min
12,3 M3/min
45 kW
26C
1,8 M3/min
0,0 M3/min
160 kW
6,9 bar
2,0 M3/min
Control over key parameters

14. Create your own dashboard

15. From guessing to knowing and understanding
Do we have enough air if our biggest compressor breaks down?
Energy efficiency – kW per produced M3?
Leakage level? – 5 or 55%?
What is our dew point?
Does the compressor produce air?
Alarm functions – pressure, dew point, leakage,
effeciency, motor starts?
Costs? – per cbm, per department, per machine, per product?
Service interval– compressors, leakage detection?
Calculated or real air consumption?
Preventive – control interstage pressure,
temperature increases?
Know Don’t
know