Compressed Air

Simplified Energy Savings

INDEX
Section I: Compressed Air Basics
What Is Compressed Air

Introduction to Compressed Air Systems

A. Compressors & Their Types

B. Dryers Types & Operation

14

C. Controls

15

D. Accessories

15

Section II: Energy Efficiency & Energy Saving

Compressed Air Costs

17

A. Lifetime Compressed Air Cost

17

B. Cost Per Year

19

C. Cost for Specific End-Uses

20

Factors Affecting Energy Efficiency

20

Achieving Energy Efficiency

23

A. Understand Your System

23

B. Conservation Strategies

25

C. System Control Strategies

26

D. Compressed Air Storage Strategies

28

E. Engineering End Uses

29

F. Conducting Self-Assessments

31

G. Engage External Experts

32

H. Implement Solutions

32

Section III: Air Efficiency Solutions

Compressed Air Audits

33

Master Air Controls

35

CountAIR

37

Free Air Delivery Meter

39

AirMon

41

Section IV: ACHIEVING ENERGY EFFICIENCY CASE STUDIES

Compressed Air Audit at a 500 MW Thermal Power Plant

43

Controlling Demand in an Automobile Plant in North India

44

Compressed Air Audit at an FMCG Plant in Sri Lanka

45

Compressed Air Leak Audit in Refinery

47

Annexures
Using the Self-Assessment Form

48

Compressed Air Self-Assessment Form

51

Compressed Air Questionnaire

53

FORBES MARSHALL | 3

Compressed Air Basics

Compressed air is used widely throughout industry and is often considered
the fourth utility at many facilities. Almost every industrial plant, from a small
machine shop to an integrated iron and steel plant, has some type of compressed
air system, and in many of those compressors use more electricity than any other
type of equipment. In many cases, the compressed air system is so vital that the
facility cannot operate without it.
Compressed air systems consist of a supply side, which includes compressors and
air treatment, and a demand side, which includes distribution and storage systems
and end-use equipment. These systems power a variety of equipment, including
machine tools, material handling and separation equipment, and spray painting
equipment.
While there are applications that require the use of compressed air, many uses
of compressed air can be eliminated to save money. Calculating the cost of
compressed air in your facility can help you justify system improvements that
increase energy efficiency. This page offers tips for increasing your compressed air
systems efficiency and decreasing costs.
Plant air compressor systems can vary in size from a small unit of 5 horsepower
(hp) to huge systems with more than 50,000 hp. Inefficiencies in compressed air
systems can therefore be significant Energy losses existing in these systems can
range from 20 to 50 percent or more of electricity consumption. For many facilities
this is equivalent to lakhs of Rupees (Rs) of wastage, and potential annual savings,
depending on use. A properly managed compressed air system can save energy,
reduce maintenance, decrease downtime, increase production throughput, and
improve product quality.
A properly managed supply side will result in clean, dry, stable air being delivered
at the appropriate pressure in a dependable, cost-effective manner. A properly
managed demand side minimizes wasted air and uses compressed air for
appropriate applications. Improving and maintaining peak compressed air system
performance requires addressing both the supply and demand sides of the system
and how the two interact.

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What Is Compressed Air?!

Compressed air is a form of stored energy that is used to operate machinery,
equipment, or processes. Compressed air is used in most manufacturing and some
service industries, often where it is impractical, expensive or hazardous to use
electrical energy directly to supply power to tools and equipment.
Powered by electricity, a typical air compressor takes approximately 7 volumes of
air at atmospheric conditions, and squeezes it into 1 volume at elevated pressure
(about 100 psig/7 bar). The resulting high pressure air is distributed to equipment
or tools where it releases useful energy to the operating tool or equipment as it is
expanded back to atmospheric pressure.
In the compression process, and the subsequent cooling of the air to ambient
temperatures, heat and moisture are released as by-products, as illustrated in the
figure below.
Heat of
Compression

Air Compressor
+
ENERGY

1 Cubic Unit at
Approximately 7 times
Atmospheric Pressure
7 Cubic Units of Air at:
Atmospheric:Pressure

Moisture

Figure 1: Conversion of Atmospheric Air into Compressed Air

Depending on the application, excessive moisture in compressed air needs to be

managed as it can cause problems with piping and end use equipment.

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Introduction to Compressed Air Systems!

Compressed air systems consist of a number of major subsystems and components.
Compressed air systems can be subdivided into the Supply side and the Demand
side.
The Supply side includes compressors, air treatment and primary storage. A
properly managed supply side will result in clean, dry, stable air being delivered at
the appropriate pressure in a dependable, cost effective manner. Major compressed
air supply subsystems typically include the air intake, air compressor (fixed speed
and/or variable speed), aftercooler, motor, controls, treatment equipment and
accessories.
The Demand side includes distribution piping, secondary storage and end use
equipment. A properly managed demand side minimizes pressure differentials,
reduces wasted air from leakage and drainage and utilizes compressed air for
appropriate applications. Distribution piping systems transport compressed air
from the air compressor to the end use point where it is required. Compressed air
storage receivers on the demand side can also be used to improve system pressure
stability.
As a rule of thumb, for every horsepower (HP) in the nameplate capacity,
the air compressor will produce approximately 4 standard cubic feet per
minute (scfm).
A simplified diagram illustrating how some of the major components are connected
is shown in Figure below.
Compressed air is used for a diverse range of commercial and industrial applications.
As it is widely employed throughout industry, it is sometimes considered to be the
fourth utility at many facilities.
It has been common practice in the past to make decisions about compressed air
equipment and the end uses based on a first cost notion. However, ongoing energy,
productivity and maintenance costs need to also be considered for calculating
system costs. In other words, best practice calls for decisions to be based on the
life cycle cost of the compressed air system and components.

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Improving and maintaining peak compressed air system optimization requires

addressing both the supply and demand sides of the system and understanding
how the two interact.
Optimal performance can be ensured by properly specifying and sizing equipment,
operating the system at the lowest possible pressure, shutting down unnecessary
equipment, and managing compressor controls and air storage. In addition, the
repair of chronic air leaks will further reduce costs.
For a typical compressed air end use, like an air motor or diaphragm pump, it takes
about 10 units of electrical energy input to the compressor to produce about one
unit of actual mechanical output to the work.
For this reason other methods of power output, such as direct drive electrical
motors, should be considered first before using compressed air powered equipment.
If compressed air is used for an application, the amount of air used should be the
minimum quantity and pressure necessary, and should only be used for the shortest
possible duration. Compressed air use should also be constantly monitored and
re-evaluated.
End Use
Equipment
Zero Air
Drain

Air
Intake

Aftercooler
Air Compressor 1
Zero Air
Drain

Air
Intake

Zero Air
Drain

Air Compressor 2
(Variable Speed)

Wet
Receiver

Filter
Air Dryer

Dry
Receiver

Pressure
Controller
(Optional)

Aftercooler

Zero Air
Drain

End Use
Equipment

Figure 2: Common Air Compressor System Components

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Air
Distribution
Pipes to
Plant

A. Compressors & Their Types

There are two basic compressor types: Positive-Displacement and Dynamic.
In Positive-Displacement compressors, a given quantity of air or gas is
trapped in a compression chamber and the volume it occupies is mechanically reduced, causing a corresponding rise in pressure prior to discharge. At
constant speed, the air flow remains essentially constant with variations in
discharge pressure.
Dynamic compressors impart velocity energy to continuously flowing air or
gas by means of impellers rotating at very high speeds. The velocity energy is
changed into pressure energy both by the impellers and the discharge volutes
or diffusers. In the centrifugal-type dynamic compressors, the shape of the
impeller blades determines the relationship between air flow and the pressure
(or head) generated.
Compressors

Positive Displacement

Reciprocating

Single-Acting

Dynamic

Rotary

Helical-Screw

Liquid-Ring

Centrifugal

Scroll

Axial

Slliding-Vane

Lobe

Double-Acting

Figure 3: Types of Compressors

Positive Displacement Compressors

These compressors are available in two types: reciprocating and rotary.
I. Reciprocating compressor
In industry, reciprocating compressors are the most widely used type for both
air and refrigerant compression (see Figure 5). They work on the principles of

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a bicycle pump and are characterized by a flow output that remains nearly
constant over a range of discharge pressures. Also, the compressor capacity
is directly proportional to the speed. The output, however, is a pulsating one.
Piston
Cylinder

Connecting Rod
Crankshaft

Spring Loaded
Suction Valve

Piston Rings

Spring Loaded
Discharge Valve

Suction
Line

Discharge
Line

Figure 4: A cross-sectional view of a reciprocating compressor

Reciprocating compressors are available in many configurations, the four most

widely used are horizontal, vertical, and horizontal balance-opposed and tandem. Vertical type reciprocating compressors are used in the capacity range
of 50 150 cfm. Horizontal balance opposed compressors are used in the
capacity range of 200 5000 cfm in multi-stage design and up to 10,000 cfm
in single stage designs.
The reciprocating air compressor is considered single acting when the compressing is accomplished using only one side of the piston. A compressor using
both sides of the piston is considered double acting.
A compressor is considered to be single stage when the entire compression is
accomplished with a single cylinder or a group of cylinders in parallel. Many
applications involve conditions beyond the practical capability of a single compression stage. Too great a compression ratio (absolute discharge pressure/
absolute intake pressure) may cause excessive discharge temperature or other
design problems. Two stage machines are used for high pressures and are
characterized by lower discharge temperature (140 to 160oC) compared to
single-stage machines (205 to 240oC).

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Intercooler

Outlet

Inlet

First Stage
(Low Pressure)

Second Stage
(Higher Pressure)

Figure 5: View of a multistage compressor

For practical purposes most plant air reciprocating air compressors over 100
horsepower are built as multi-stage units in which two or more steps of compression are grouped in series. The air is normally cooled between the stages
to reduce the temperature and volume entering the following stage. Reciprocating air compressors are available either as air-cooled or water-cooled in
lubricated and non- lubricated configurations, may be packaged, and provide
a wide range of pressure and capacity selections.
II. Rotary compressor
Rotary compressors have rotors in place of pistons and give a continuous pulsation free discharge. They operate at high speed and generally provide higher
throughput than reciprocating compressors. Their capital costs are low, they
are compact in size, have low weight, and are easy to maintain. For this reason

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they have gained popularity with industry. They are most commonly used in
sizes from about 30 to 335 hp or 22 to 250 kW.
Types of rotary compressors include:
1. Lobe compressor (roots blower)
2. Screw compressor (rotary screw of helical-lobe, where male and female
screw rotors moving in opposite directions and trap air, which is compressed
as it moves forward, see Figure Below)
3. Rotary vane / sliding- vane, liquid-ring, and scroll-type

Figure 6: View of screw compressor

Rotary screw compressors may be air or water-cooled. Since the cooling takes
place right inside the compressor, the working parts never experience extreme
operating temperatures. The rotary compressor, therefore, is a continuous
duty, air cooled or water cooled compressor package.
Because of the simple design and few wearing parts, rotary screw air compressors are easy to maintain, operate and provide great installation flexibility.
Rotary air compressors can be installed on any surface that will support the
static weight.

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Dynamic Compressors
The centrifugal air compressor (see Figure 7) is a dynamic compressor, which
depends on transfer of energy from a rotating impeller to the air. The rotor
accomplishes this by changing the momentum and pressure of the air. This
momentum is converted to useful pressure by slowing the air down in a stationary diffuser. The centrifugal air compressor is an oil free compressor by
design. The oil lubricated running gear is separated from the air by shaft seals
and atmospheric vents.
The centrifugal is a continuous duty compressor, with few moving parts, that
is particularly suited to high volume applications-especially where oil free air
is required.
Centrifugal air compressors are water-cooled and may be packaged; typically
the package includes the after-cooler and all controls.

Figure 7: View of centrifugal compressor

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B. Dryers Types & Operation

Moisture content in compressed air is harmful to most end-use applications
and must be removed from the system at the earliest. Dryers help to eliminate
any remaining moisture in the compressed air by using either a refrigerated
condenser or a desiccant.
Compressors Air Dryers

Deliquessent

Refrigerated

Desiccant

Direct Expansion

Internal Heated

Cycling / Thermal
Mass

External Heated

Blower Purge
Heat of
Compression

Figure 8: Types of Dryers

The two most commonly types of dryers prevalent in industries are Refrigerant
and Dessicant dryers
I. Refrigerant Dryers
Air Outlet

4
Air Intlet

Pe-Cooler/Reheatere

Moisture Separator

Air-to-Water/Glycol
Heat Exchanger

Defroster & Solenoid Valve

Evaporator
Condesnsor

Compressor

Isolation
Valves

Suction
Accumulator

Pump

Figure 9: View of a Refrigerant Dryer

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Cold bank
Storage

Refrigerated air dryers deliver dry air by cooling the compressed air down, thereby aiding condensation after which the condensed moisure is removed via a
separator. These dryers typically use two heat exchangers one air-to-refrigerant
and one air-to-air to bring down the temperature of the incoming air.
II. Dessicant Dryers
These type of driers push compressed air through a system of highly absorbent
dessicant gels which remove any moisture and let out dry air. Once these gels are
saturated with extracted moisture, compressed air is used to purge the moisture
Adsorption Drying
WET AIR

DRY DESICCANT

DRY AIR

Regeneration
WET AIR

DRY DESICCANT

DRY AIR

Figure 10: Working of a Dessicant dryer

C. Controls
Controls serve to adjust the amount of compressed air being produced to maintain constant system pressure and manage the interaction between system components. Air filters and air dryers remove moisture, oil and contaminants from
the compressed air. Compressed air storage (wet and dry receivers) can also be
used to improve system efficiency and stability. Accumulated water is manually or
automatically discharged through drains. Optional pressure controllers are used to
maintain a constant pressure at an end use device.
D. Accessories

Moisture Separator: removes liquids from the compressed air

Airline Filter: removes solids and liquids from the compressed air stream.
Can be placed throughout the system.
Condensate Trap: collects and discharges liquid that condenses out of the
air stream. It is an integral part of after-coolers, dryers and separators

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Energy Efficiency & Energy Saving

With 73% of the cost of a compressor due to energy use, significant cost savings
will be made by improving energy efficiency, as well as the added benefits of
improving the performance of your system and reducing your organisations
carbon footprint.
Energy efficiency will also increase the proportion of compressed air that is used
for production and minimise unnecessary wastage, again resulting in significant
cost savings. An example of just how much demand on the compressed air system
can be wasted is shown in figure below.

Artificial
demand 6%

System
inefficiencies 8%

Artificial
demand 16%
Production
demand 73%

Leaks 19%
Figure 11: Compressed Air Usage Patterns

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This Is What An Ordinary Compressed Air Network Looks Like

Compressed Air
Supply

Compressed
Air Tank

Aftercooler

Leaks

Leaks
High Specific
Power

Pr drop

Air
Dryer

Abrasive Blast
Cabinet

Under Loaded
resulting poor
performance

Pr drop

Artificial demand &

Uncontrolled operations

Leaks

Improper piping
& over pressurization

Figure 12: Typical issues of a Compressed Air System

Compressed Air Costs!

The given tendency in industry today is to look at compressed air costs solely in
terms of the equipment purchase costs. However, the real cost to measure is the
Lifetime Compressed Air Cost. Calculating the cost of compressed air can help
you justify improvements for energy efficiency.
A.Lifetime Compressed Air Cost
of a compressor accurately measures the real cost of installing, operating and
maintaining a compressors over a ten year period, and includes the capital
(equipment purchase) cost, installation costs, maintenance costs, and the energy costs. This section will help you to understand how much it costs to
produce and use compressed air. Over the first ten years of life of a typical air
cooled compressor (see figure below), with a two shift operation, the operating cost - energy and maintenance - will equal about 80% of the total lifetime
cost. The cost of the original equipment and installation will only account for
the remaining 20%.

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Maintenance
Cost 7%

Capital cost
18%

Installation
cost 2%

Energy cost
73%

Figure 13: Typical Lifetime Ownership Cost of Compressed Air Systems

We can thereby arrive at the actual expense of using compressed air in any
compressed air system, and therefore the need to identify and correct any
possible losses in energy efficiency of compressed air systems.
The figure below (Fig. 3) illustrates the typical losses associated with producing
and distributing compressed air. Assuming 100 HP energy input, approximately 91 HP ends up as losses, and only 9 HP as useful work. In other words, about
90% of the energy to produce and distribute compressed air is typically lost.

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100 HP
Energy
Input

Heat of Comression and

Compressor Losses (~80 HP)

Desiccant Dryer (~3 HP)

Filters and Leaks (~6HP)
Pneumatic to Machanical Conversion (~2 HP)
Useful Energy Output (9 HP)

Figure 14: Compressed Air Energy Input and Useful Energy Output

B. Cost Per Year

To find the annual cost of electricity used to power a compressed air system, calculate the cost for running the system under loaded and unloaded conditions.
For each, multiply:
Horsepower (hp)
Conversion factor 0.746 kW/hp
Total operating hours per year (hr/yr)
Cost per kilowatt-hour (Rs./kWh)
% time fully-loaded or unloaded
% full-load hp, loaded or unloaded
Divide the product by the motors efficiency.
(hp) * (0.746 kw/hp) * (hr/yr) *(Rs/kWh) *(% time) *(% full-load bhp)
motor efficiency

FORBES MARSHALL | 19

C. Cost for Specific End Uses

Calculate the cost of compressed air for specific end uses. This allows you to
determine if compressed air should be used in specific applications (ie. as fans or
blowers), or if other electric-motor operated equipment would be more efficient.
First calculate the volume of air produced annually for a specific operation by
multiplying:
horsepower (hp)
cubic feet per minute per horsepower (cfm/hp)
total operating hours per year (hr/yr)
60 minutes per hour (60 min/hr)
% time fully loaded
% full-load horsepower
Volume of air produced annually
(hp) * (cfm/hp) * (hr/yr) * (60 min/hr) * (% time) *(% full-load hp)

Then calculate the cost per 1,000 cubic feet (cf) by dividing the total energy
cost to operate the air compressor by the volume of air produced annually,
then multiply by 1,000.
Cost per year / Volume of air products * 1000 cf

Factors Affecting Energy Efficiency!

Efficiency of Compressed Air systems can be affected by a wide ranging set of
factors. In order to maintain efficiency of your compressed air network you must
take care of the following
A. Location of Compressor - The location of air compressors and the quality of air drawn by the compressors will have a significant influence on the
amount of energy consumed. Compressor performance as a breathing machine improves with cool, clean, dry air at intake.
B. Air Intake Quality Intake air that is contaminated by dust or other contaminants can increase wear and tear of compressors, causing loss of efficiency. Similarly, higher intake temperature of air means lower volumetric efficiency of compressors. As a rule for every 4oC rise in air temperature results in 1%

FORBES MARSHALL | 20

higher power consumption from the compressors.

C. Pressure Drops in Air Filter Mismatched or choked filters cause pressure drop across the filters. The table below shows affect of pressure drop on
power consumption
Pressure Drop Across air filter (mm WC)

Increase in Power Consumption (%)

200

1.6

400

3.2

600

4.7

800

7.0

D. Elevation/Altitude Compressors located at higher altitude consumer

more power than those at sea level as the compression ratios are higher.
Altitude Meters

Barometric
Pressure milli bar*

Percentage Relative Volumetric

Efficiency Compared with Sea Level
At 4 bar

At 7 bar

Sea level

1013

100.0

100.0

500

945

98.7

97.7

1000

894

97.0

95.2

1500

840

95.5

92.7

2000

789

93.9

90.0

2500

737

92.1

87.0

*1 milli bar - 1.01972 x 10-3 kg/cm2

E. Inter and After-Coolers Inadequate cooling negatively affects the efficiency of the compressors. Ideally, the temperature of the inlet air at each stage
of a multi-stage machine should be the same as it was at the first stage. With
increased temperature, the volume handled is higher, therefore causing higher
energy consumption. With excess cooling however, there is a danger of further
condensation and inadequate moisture removal.

FORBES MARSHALL | 21

F. Optimising Delivery Pressure

i. Reducing Delivery Pressure Operators tend to deliver a higher set pressure to the demand side than what is absolutely necessary. This can be optimised by a careful study of the requirement for each equipment, and pressure
drop between generation and demand side.
ii. Compressor Modulation by Optimum Pressure Setting In case of
multiple compressors running to satisfy varying demand, proper selection of a
right combination of compressors and optimal modulation of different compressors can conserve energy. The pressure set points (loading & unloading)
should be such that the smallest compressor modulates first to cater to the
varying demand.
iii. Segregating Low & High Pressure Requirements Reducing from a
common pressure to feed low-pressure requirements is a waste of energy. It is
advisable to segragate the two different lines.
iv. Pressure Drop in Delivery Lines The layout of the distribution lines has
a significant impact, as an inefficient design can cause pressure drops.
Such imbalances between demand requirement and supply cause excess energy to be consumed, without any productive use.
For every 1 Bar of excess pressure generated, the energy consumption of a
compressed air system goes up by an average 7%

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G. Leakage Compressed air leaks are the single largest source of losses in
most compressed air networks. A study by the Buereau of Energy Efficiency
(Govt. of India) states that up to 30% of excess energy consumed in compressed air systems is directly due to leaks. While most leaks are hard to find,
they are relatively easy to identify with the right equipment.
H. Condensate Removal Presence of moisture reduces the efficiency of
compression by reducing the available air to be compressed. Similarly, it has
the potential to harm the end-use equipment, if it is not safe to used as such.
I.Maintenance Practices Regular check-ups and servicing of compressors is
vital to maintain good health and therefore higher efficiency. Periodic servicing
and replacement of parts like filters, traps, lubrication oil etc has to be undertaken. One must inspect the air-end fo the compressors as well.

Achieving Energy Efficiency!

Reducing energy consumption of ones compressed air system requires a series
of measures to be taken from the compressed air generation to the consumption
sides. Major consumers of compressed such as cement, textiles and automobiles
often face problems compressed air related issues solely from the utility or the user
sides. In such setups, due to the scale of the issue it is imperative that the two sides
work together in order to achieve lower losses and better efficiency.

FORBES MARSHALL | 23

A. Understand Your System

Before implementing energy reduction strategies, be familiar with all aspects
of your compressed air system.
System Supply Analyze the supply side of your compressed air system for
the types of compressors used and the type, suitability and settings of capacity
controls and other operating conditions. Understand the basic capabilities of
the system and its various modes of operation. Verify that air compressors are
not too big for end uses. For example, an air compressor is oversized if the end
use only requires air pressure that is 50 % of the pressure that the compressor
is capable of producing. Once the big picture is in view, supply side operating
conditions can be modified, within the constraints of the compressed air unit,
to better match the demand side uses of compressed air.
System Demand - Identify all the uses of compressed air in the plant. Quantify
the volume of air used in each application and generate a demand profile, quantity
of air used as a function of time, for the compressor. Equipment specifications for
operations that use air are good resources for obtaining data on air volume use
rates. The profile highlights peak and low demand. A general assessment of compressed air use will help identify inappropriate uses of air.
Air Quality - Air quality is determined by the air dryness and contaminant level
required by end uses. Learn the actual dryness level needed and the maximum
contaminant level allowed for reliable production. Overtreating air beyond the
required dryness and allowable contaminant level wastes money and energy.
Pressure Requirements - The minimum required discharge pressure level
must take into account the different pressure ratings of compressed air applications and processes as well as the pressure drops from components in the
system. Too often, low or fluctuating pressure at end uses is misdiagnosed as
not enough discharge pressure
System Diagram - Develop a sketch of your compressed air systemincluding compressors, air supply lines with dimensions, and compressed air end
usesto provide an overall view of the entire compressed air process.
Distribution system - Investigate the distribution system for any problems
related to line size, pressure loss, air storage capacity, air leaks and condensation drains. Verify that all condensation drains are operating properly because
inadequate drainage can increase pressure drop across the distribution system.

FORBES MARSHALL | 24

Maintenance - Evaluate maintenance procedures, records and training. Ensure that procedures are in place for operating and maintaining the compressed air system, and that employees are trained in these procedures
B. Conservation Strategies
Identify easy to implement energy conservation opportunities in your compressed air system by conducting a walk-through assessment. Simple conservation opportunities can result in savings up to 25% of the current cost to run
the compressed air system.
Leaks - Routinely check your system for leaks. A distribution system under
100 pounds-per-square-inch gauged (psig) of pressure, running 40 hours per
week, with the equivalent of a quarter-inch diameter leak will lose compressed
air at a rate of over 100 cfm costing over Rs. 173348 per year. In noisy environments an ultrasonic detector may be needed to locate leaks.
Compressor pressure - The compressor must produce air at a pressure high
enough to overcome pressure losses in the supply system and still meet the
minimum operating pressure of the end use equipment. Pressure loss in a
properly designed system will be less than 0.2 PSI of the compressors discharge pressurefound on a gauge on the outlet of the compressor. If pressure loss is greater than 0.2 PSI, evaluate your distribution system and identify
areas causing excessive pressure drops. Every two pounds-per-square-inch decrease in compressor pressure will reduce your operating costs 1.5%.
Identify artificial demands - Artificial demand is created when an end use is
supplied air pressure higher than required for the application. If an application
requires 50 psi but is supplied 90 psi, excess compressed air is used. Use pressure
regulators/demand controllers at the end use to minimize artificial demand.
Inappropriate use of compressed air - Look for inappropriate uses of compressed air at your facility. Instead of using compressed air, use air conditioning
or fans to cool electrical cabinets; use blowers to agitate, aspirate, cool, mix,
and inflate packaging; and use low-pressure air for blow guns and air lances.
Disconnect the compressed air source from unused equipment.
Heat Recovery - As much as 80 to 90% of the electrical energy used by an air
compressor is converted to heat. A properly designed heat recovery unit can
recover 50 to 90% of this heat for heating air or water. Approximately 50,000

FORBES MARSHALL | 25

British thermal units (Btus) per hour is available per 100 cfm of compressor capacity when running at full load. For example, consider a 100 hp compressor
that generates 350 cfm at full load for 75% of the year. If 50% of heat loss
is recovered to heat process water, the savings, at 31.04 per therm, would be
about Rs. 2,54,528 per year in natural gas.
Inlet Air Filters - Maintain inlet air filters to prevent dirt from causing pressure
drops by restricting the flow of air to the compressor. Retrofit the compressor
with large-area air intake filters to help reduce pressure drop.
Compressor Capacity - If your compressor is oversized add a smaller compressor and sequence-controls to make its operation more efficient when
partially loaded. Sequence-controls can regulate a number of compressors to
match compressed air needs, as they vary throughout the day.
Cooler Intake Air - When in taking cooler air, which is more dense, compressors use less energy to produce the required pressure. For example, if 90 degree
F intake air is tempered with cooler air from another source to 70 degree F, the
20 degree F temperature drop will lower operating costs by almost 3.8%.
V-belts - Routinely check the compressors v-belts for proper tightness. Loose
belts slip more frequently which reduces compressor efficiency.
C. System Control Strategies
Improving and maintaining compressed air system performance requires not
only addressing individual components, but also analysing both the supply
and demand sides of the system and how they interact, especially during periods of peak demand. This practice is often referred to as taking a systems
approach because the focus is shifted away from components to total system
performance.
Matching Supply with Demand - With compressed air systems, system dynamics (changes in demand over time) are especially important. Using controls, storage, and demand management to effectively design a system that
meets peak requirements but also operates efficiently at part-load is key to a
high performance compressed air system. In many systems, compressor controls are not coordinated to meet the demand requirements, which can result
in compressors operating in conflict with each other, short-cycling, or blowing
offall signs of inefficient system operation.

FORBES MARSHALL | 26

Individual Compressor Controls - Controls such as start/stop and load/unload respond to reductions in air demand by turning the compressor off or
unloading it so that it does not deliver air for periods of time. Modulating
inlet and multi-step controls allow the compressor to operate at part-load and
deliver a reduced amount of air during periods of reduced demand. Variable
speed controls reduce the speed of the compressor in low demand periods.
Compressors running at part-load are generally less efficient than when they
are run at full-load.
Multiple Compressor Controls - Systems with multiple compressors should
use more sophisticated controls to orchestrate compressor operation and air
delivery to the system. Network controls use the on-board compressor controls microprocessors linked together to form a chain of communication that
makes decisions to stop/start, load/unload, modulate, and vary displacement
and speed. Usually, one compressor assumes the lead role with the others being
subordinate to the commands from this compressor. System master controls
coordinate all of the functions necessary to optimize compressed air as a utility.
System master controls have many functional capabilities, including the ability to
monitor and control all components in the system, as well as trending data, to
enhance maintenance functions and minimize costs of operation. Most multiple
compressor controls operate the appropriate number of compressors at full-load
and have one compressor trimming (running at part-load) to match supply with
demand.
Pressure/Flow Controllers - Pressure/Flow Controllers (P/FC) are system pressure controls that can be used in conjunction with the individual and multiple
compressor controls described above. A P/FC does not directly control a compressor and is generally not part of a compressor package. A P/FC is a device that
serves to separate the supply side of a compressor system from the demand side,
and requires the use of storage. Controlled storage can be used to address intermittent loads, which can affect system pressure and reliability. The goal is to deliver
compressed air at the lowest stable pressure to the main plant distribution system
and to support transient events as much as possible with stored compressed air.
In general, a highly variable demand load will require a more sophisticated control
strategy to maintain stable system pressure than a consistent, steady demand
load.

FORBES MARSHALL | 27

D.Compressed Air Storage Strategies

Compressed air storage can allow a compressed air system to meet its peak
demand needs and help control system pressure without starting additional
compressors. The appropriate type and quantity of air storage depends on
air demand patterns, air quantity and quality required, and the compressor
and type of controls being used. An optimal air storage strategy will enable a
compressed air system to provide enough air to satisfy temporary air demand
events while minimizing compressor use and pressure.
The use of air receivers is especially effective for systems with shifting air demand patterns. When air demand patterns are variable, a large air receiver can
provide enough stored air so that a system can be served by a small compressor and can allow the capacity control system to operate more effectively. For
systems having a compressor operating in modulation to support intermittent
demand events, storage may allow such a compressor to be turned off. By
preventing pressure decay due to demand events, storage can protect critical
end-use applications and prevent additional units from coming online.
Air entering a storage receiver needs to be at a higher pressure level than the
system pressure. A good air storage strategy will allow the differential between these two pressure levels to be sustained. To accomplish such a pressure
differential, two types of devices can be employed: Pressure/Flow Controllers
(P/FC) and metering valves.
A P/FC is a device that serves to separate the supply side of a compressed air
system from the demand side. In a system that employs P/FCs, the compressors generally operate at or near design discharge pressure to ensure that
the P/FC receives air at a higher pressure level than it will discharge into the
system. This allows the pressure in the demand side to be reduced to a stable
level that minimizes actual compressed air consumption. P/FCs are added after
the primary receiver to maintain a reduced and relatively constant system pressure at points of use, while allowing the compressor controls to function in the
most efficient control mode and discharge pressure range. Properly applied, a
P/FC can yield significant energy savings in a system with a variable demand
load. See figure below

FORBES MARSHALL | 28

Figure 15 Compressed Air System with a Pressure/Flow Controller

For situations in which just one or a few applications have intermittent air demand, a correctly-sized storage receiver close to the point of the intermittent
demand with a check valve and a metering valve can be an effective and lower
cost alternative. For this type of storage strategy, a check valve and a tapered
plug or needle valve are installed upstream of the receiver. The check valve
will maintain receiver pressure at the maximum system pressure; the plug or
needle valve will meter the flow of compressed air to slow fi ll the receiver
during the interval between demand events. This will have the effect of reducing the large intermittent requirement into a much smaller average demand.
See Figure Below.

Figure 16 Compressed Air System with Check and Needle Valves

E. Engineering End Uses

Compressed Air directly serves processes and applications such as pneumatic
tools, pneumatic controls, and compressed air operated cylinders for machine
actuation, product cleansing and blow-off applications. Ensuring an appropriate, stable pressure level at the end-use applications is critical to the perfor-

FORBES MARSHALL | 29

mance of any industrial compressed air system. End uses that are engineered
for maximum efficiency can help provide the consistent supply of compressed
air that ensures reliable production.
To ensure the efficiency of compressed air end-use applications, a number of
steps should be taken:
Steps

Action

Description

Review pressure
Those pressure level requirements should
requirements of end- determine the system pressure level. There
use applications
is often a substantial difference in air
consumption and pressure levels required
by similar tools available from different
manufacturers, request exact figures
from each manufacturer for the specific
application.

Monitor Air Pressure

at the inlet to the
tool

Avoid the operation Operating a tool this way will consume

of any air tool at
more air than a tool that has the load
free speed with no applied.
load

Check the useful

life of each end-use
application

A worn tool will often require higher

pressure, consume excess compressed
air, and can affect other operations in the
immediate area.

Deliver moisture free

air

Presence of moisture in air to end-use

applications can lead to damage of parts and
deficiency in process.

Grouping of
applications with
similar pressure
requirements

This is a good engineering practice for

optimising compressed air network, which
will help reduce generation load.

FORBES MARSHALL | 30

Improperly-sized hoses, fittings and quick

disconnects often result in large pressure
drops. These drops require higher system
pressures to compensate, thus wasting
energy.

Investigate and
reduce the highest
point-of-use pressure
requirements

This will helps to reduce the pressure

demands in system. Also minuses the
pressure drops.

Investigate and
This permits conserving use of compressed
replace inefficient
air. By such implementations air wastage
end uses such as
can avoided by a considerable amount.
open blowing with
efficient ones such as
vortex nozzles

F. Conducting Self-Assessments
Taking steps to reduce energy efficiency of compressed air systems, requires thorough insights into the existing working parameters of the system and the potential opportunities.
The utilities manager must keep a regular check on the cost of compressed air
and the utilisation of compressed air in the right manner. Keep a check on at
least the following:
1. Lifetime cost of compressed air
2. Cost per year
3. End-Use costs
4. Pressure Delivery and Pressure Demand
5. Leakages
6. Malpractices and Inefficient Uses of compressed air
With the right tools and techniques it is fairly easy to do a basic self-assessment of ones compressed air system. It is important to be honest with ones
assessment of the existing compressed air system and keeping an open mind
about deficiencies in the practices being currently maintained.
Self-Assessment Forms, such as the one enclosed in this book, should be used
to conduct a preliminary audit of ones own compressed air system. These
will at the first-go help in identifying the most basic opportunities for saving
energy.

FORBES MARSHALL | 31

G. Engage External Compressed Air Experts

Having conducted a self-assessment of ones compressed air system, it is advised to incorporate external viewpoints for further improvements. External
experts in compressed air systems, such as Forbes Marshalls Air Efficiency
Solutions, bring with them experience gained from managing and improving
compressed air systems across many different setups and industries. The insights gained from such experience can help identify higher level opportunities
for energy efficiency and help implement solutions and Best Practices.
H. Implement Solutions
Reducing energy intake in compressed air systems can only be achieved by
taking the vital step of implementing the solutions identified by the self-assessment and audits by external experts. Moreover, beyond just initially achieving reduction in energy consumption, system managers and users have to
continuously work to ensure that these efficiency levels are sustained over a
long term.

FORBES MARSHALL | 32

Air Efficiency Solutions

Forbes Marshall has over 60 years of experience in providing solutions for energy
savings in various industries and utilities. We boast of expertise in providing energy
efficiency services for utilities such as Compressed Air, Steam, Water & Electrical system.
Forbes Marshalls Air Efficiency Solutions are comprehensive bundle of services
that help optimization of compressed air networks. Our services help identify and
define system problems, whether they are in demand, distribution or supply, and
provide solutions, allowing you to meet your return on investment goals.
We have a varied range of products for Monitoring, Controlling, Optimizing
compressed Air and Energy Conservation which offers a complete control of your
whole compressed air network and thus help to increase efficiency & reduce your
energy costs.
Our range of solutions includes compressed air audits, demand control systems,
compressor control systems, network monitoring solutions and flow meters
etc. Through our various services and solutions we have been able to support
our customers in achieving energy efficiency in diverse industrial sectors such as
Automobiles, Textiles, Cement, Power, Glass and many others.

Compressed Air Audits!

Compressed Air Audits focus on identifying the potential for increasing the
energy savings on compressed air network. Compressed air being one of the most
inefficient and costly utilities, compressed air audits bring out the various areas
that cause inefficiencies and losses in your compressed air network and lead to
wastage of energy.
Features A specialized service, focused on energy conservation
A comprehensive study of your compressed air network from generation to
consumption
Designed to identify and address a wide range of issues
Qualified, BEE certified auditing company

FORBES MARSHALL | 33

Benefits of Air Audit

It gives the complete real time scenario of complete compressed air network
Air audits leads to energy savings which can ranges from 15% to 25%
It highlights the drawbacks & artificial demands in air network, which upon
addressing gives huge cost savings
Objective:
The major goals of the audit are:

Estimating the existing power consumption, efficiency of compressors, specific power consumption for individual compressors and the system as a whole.
Study of the existing demand at various areas & operating patterns & thereby
optimizing of compressed air consumption at various points of uses.
Study of existing compressor layout, system capacitance and distribution
network,and recommend improvements, if any.
Recommend steps for potential energy conservation in all above areas and
suggest ways for optimum utilization of the compressed air system.
Study of the present supply & demand relations for process, cleaning &
instrument air system.

Methodology of Audit
In order to provide a comprehensive analysis, we analyze the quantity, quality,
reliability, repeatability, and cost of the existing compressed air system. Production
capacity at the time of audit. Over many numbers of data points we collect and the
analysis is based upon this data and plant personnel interviews and feedback.

Overview study

Audit & Data coll.

Analyse

Recommend

Helping Implement

Figure 17: Approach of a Compressed Air Audit

FORBES MARSHALL | 34

Master Air Control (MAC)!

In every industry the air demand of the plant keeps fluctuating constantly due to
intermittent use of pneumatic equipment. When the demand for compressed air
increases, the compressor responds to a low-pressure signal and starts loading.
However, there always exists a lag between the compressor getting the signal to
load and when it builds up the required pressure, and by that time the demand is
likely to have vanished. As a result, the compressor pumps air into the system till
it reaches its unload set point. This extra air that the compressor injects into the
system is purely artificial demand.
The lag in response time between demand & supply forces the compressor
operators to maintain higher level of pressure in the air system to sustain a sudden
demand. This goes towards feeding just the artificial demand. Simply lowering
supply side air pressure is also not an option, since it causes a negative impact on
production. Doing so may result in decreased production efficiencies and quality
related problems. In effect, industries end up with losses due to inefficiencies and
higher energy bills. In this situation you need a proper balancing of supply and
demand of compressed air.
Master air Control is a demand side load controller that helps control the artificial
demand in your compressed air network. Continuously fluctuating demand in the
plant causes the compressors to run in continuous load-unload cycles, and in a
higher pressure band. The MAC helps deliver a steady pressure to the demand side
and ensures that the compressors run at a steadier rate and therefore conserve
energy.
MAC is an energy saving control system, which actively helps you control the
balance across the demand and supply sides. It introduces a differential pressure
between the receiver and itself and thus creates a useful high-pressure storage.
This helps in isolating the compressors from the demand surges. Peaks in demand
are handled by MAC, rather than being directed towards the compressors. This
allows compressors to run for longer on no-load. As a result, mass of air is reduced
and a high and compressor load cycles are reduced. This decrease in compressor load
cycles is directly proportional to the decrease in energy consumed by the compressors.
Thus, due to the MAC compressors are protected from artificial demand and the

FORBES MARSHALL | 35

have to cater only to base demand, and resulting in savings on compressed air
energy consumption.
Furthermore, a constant pressure is now delivered to all plants and pneumatic
equipment, increasing quality and productivity in production processes.

Figure 18: Master Air Control (MAC)

Figure 19: Forbes Marshall- MAC installation Scheme

Benefits of Master Air Control

Saves energy consumed by air compressors by cutting artificial demand
for air
Reduction in compressor loading & induces higher unloading period
Separates compressors from demand side peaks & lows, thus prevents
compressor cycling to minimal
Consistent air pressure delivery to demand side
Enhanced useful air storage capacity
Accommodates to any make of compressor
Demand reduction tends to reduce leakages in plant

FORBES MARSHALL | 36

Features of Master Air Control

HMI for better GUI
History & trending feature
Fail safe operation
Accurate pressure control
Provision of pressure control via addition of air demand meter
Highly responsive to fine changes in demand

CountAir The Complete Air System Monitor!

Compressed air networks tend to be spread out over wide areas, and the expanse
of the systems makes it difficult to monitor closely. However, compressed air being
an energy intensive utility, it is imperative that the utility is monitored closely and
completely.
Count Air is a central monitoring solution for your entire compressed air network.
It helps you monitor even the most remote corner of your network through
instruments such as flow meters, pressure transmitters, etc. Through its various
features it helps you identify and address issues before they turn into problems,
thus saving on downtime.
It offers features like trends, history, graphs, alarms etc. This work equally well in
wired or wireless mode.
Benefits of CountAIR
Real-time specific compressor & machine data
Deviations of any machine or area from its trend line and rated
consumption
An overall plant demand overview
Presence of leakages in your distribution lines
Historical trends of each area/unit with graphs
Identification of unaccounted losses in the system

FORBES MARSHALL | 37

Figure 20: Sample schematic for monitoring of compressed air network

Figure 21: CountAIR User Interface

FORBES MARSHALL | 38

Figure 22: CountAIR Flowmeter Individual Display

Features of CountAIR
Forbes Marshalls CountAIR is the ideal solution for complete monitoring of
your compressed air network from compressors to utility points
It continuously keeps track of the generation of each compressor, and each
consumption point , and keeps you informed on the overall system efficiency
It enables you to monitor because an unmonitored consumption side leaves you
with an incomplete picture

Free Air Delivery Meter FAD Meter!

FAD Meter is one of the most accurate solutions available for compressed
air efficiency monitoring. Due to its in-built online pressure and temperature
compensation it gives a highly accurate reading of your compressors actual output
and can monitor its health and efficiency continuously.
It is prfectly suitable for measurement of compressed Air, It replaces older
technologies like the orifice plate or DPT system by combining pressure/temparature
sensors in a single instrument. The figure below shows how the FAD meter replaces
conventional orifice/DPT systems.

FORBES MARSHALL | 39

Benefits of FAD Meter

Accuracy of +/- 1% of measured value
Optimum process reliability thanks to Flodoc Intelligent Signal Processing
stable readings, free of external disturbances
Reconcile generation with consumption and losses
Reduce downtime through preventive maintenance
Avoid periodical overhauls, When not necessary
Better process control resulting in enhanced product quality
Features of FAD Meter
Forbes Marshall FAD meter is a Vortex type with online temperature and
Pressure compensation
It is the most accurate and the most effective way to measure and monitor
compressor efficiency
Enables you to monitor health of your compressor

Figure 23: Free Air Delivery Meter

FORBES MARSHALL | 40

Figure 24: FAD Vs Convential Flowmeters

AirMon!
AirMon is custom-designed flow meter for distribution line metering. It is easy
to install and convenient to use. Once fixed on any distribution line, it gives very
accurate inputs on the consumption of air through that line. Moreover, it is a
budget-friendly flow meter.
It is an innovative cost-effective solution for monitoring of compressed air on plant
lines. Its microprocessor-based electronics features software designed jointly by
a team of flow metering and compressed air experts. This gives you the most
accurate solution for compressed air utility metering.
Benefits of AirMon
Specialized solution for utility metering of compressed air
Accuracy +/- 3% of measured value
Airmon facilitates remote monitoring of the key data which is conveniently viewed by the operators
Maintenance free sensor design
User friendly- No need of Expert operator
Cost effective solution.

FORBES MARSHALL | 41

Features of AirMon
It is an innovative cost-effective solution for monitoring of compressed air on
plant lines
It makes users data available with minimum hardware/electronics without
compromising on the accuracy, reliability and durability
Its online pressure and temperature compensation makes it the most practical solution that helps to tally the compressed air usage at the distribution line

Figure 25: AirMon

Beyond these standardised solutions, Forbes Marshall offers a wide variety of

customised solutions which will help the compresses air system managers monitor
and control their networks in a more comprehensive manner, and help keep energy
efficiency levels high.
You can get further details of our solutions on our website www.forbesmarshall.
com/airaudits, or email us at [email protected].

FORBES MARSHALL | 42

Achieving Energy Efficiency Case Studies!

Compressed Air Audit at a 500 MW Thermal Power Plant!
Forbes Marshalls Air Efficiency Solutions team conducted an Energy Audit of
Compressed Air System at one 250 MW unit of 02X 250 MW Thermal Power Plant
in Maharashtra in December 2013.
Compressed air is one of the most critical utility in the plant. Compressed air is
widely used across the plant for applications such as Instrument Air, Service Air &
Ash Conveying System. The total existing annual power cost for compressed
air system was Rs. 2.25 Crores/annum. The chief purpose of audit was study
and analysis of the existing system, estimate the saving potential and provide
appropriate energy conservation solutions to achieve the savings.
As part of the audit, the Air Efficiency Solutions team carried out Power Profiling
of compressors, Compressor Efficiency Measurement, Pressure Profiling & Mapping
of the entire compressed air network, Flow Profiling of the Demand side, Air Leak
Detection, Air Pipeline Network Study. Analysis of the data collected during the
audit revealed huge potential for reduction in energy consumption by the
compressed air system. The true productive demand was identified to be
only around 77%, with losses contributing to excess 23% energy
consumption.

Percentage Demand Analysis

Leakage
10%
Artifical Deamand
controlled by MAC
9%

Leakage
Arifical Demand controlled by MAC
Losses In Dryers
Actual Demand
Actual Demand
77%

Losses in Dryers
4%

FORBES MARSHALL | 43

On the generation side, the main potential for energy conservation was reduction
in pressure drop by replacing existing desiccant dryers with refrigerant dryers. This
change in technology presented not only short-term savings, but also long-term
benefits in system efficiency. Additionally, we recommended replacement of two
of the existing reciprocating compressors with a single Centrifugal Compressor of
higher capacity. Centrifugal compressors are ideal for processes with high air flow
demand since their average specific power consumption (0.16 KW per CFM) is
lower than that of reciprocating compressors (0.2 KW per CFM).
On the Demand Side, we recommended installation of the Master Air Control
(demand controller) in order to reduce excess pressurization and artificial demand
in existing system without affecting the plant operations. This offered a savings
of approximately 9.5% of the annual compressed air electricity cost. In
addition to this, general guidelines, tips and techniques for maintaining overall
system were also recommended in order to run compressed air system efficiently
for longer period. Including other solutions like arresting Compressed Air leaks
and installation of No-Loss Drain Traps, the total achievable energy saving
potential was up to 22.5% of the annual energy costs. Savings in terms of
cost was Rs.51 Lacs/annum with a payback period of 6 months only.

Controlling Demand in an Automobile Plant in North India!

Forbes Marshall Air Efficiency Solutions team implemented the Master Air Control
at a Two Wheeler Manufacturing Automobile Plant in North India in May 2014 and
delivered greater savings than those committed.
Compressed Air was mainly used in this plant as Instrument Air for operating
pneumatic machine tools. The plant management had identified the demand side
of the compressed air system as an area where they wanted solutions to reduce
energy consumption. According to plant management, the plant demand was
very fluctuating and power consumption was higher than design and benchmark
standards. Hence, after discussions with the plant management we conducted an
audit f the compressed air system to get a precise idea about existing scenario.
After analyzing the collected data, we found significant energy saving potential
due to excess pressure generation, pressure fluctuations and artificial demand.
The existing average pressure at generation was around 6 Bar, whereas the actual

FORBES MARSHALL | 44

minimum required pressure was found to be only 5.4 Bar. This presented an
opportunity to conserve energy by ensuring reduction in pressure delivery while
catering to the fluctuating demand.
To achieve this saving, Forbes Marshalls Master Air Control (Demand
Controller) was recommended with a minimum saving potential of 7.3% in
power and compressed air consumption. After installation of Master Air
Control on the main header line after the air receiver, this controller ensured
reduction of the excess air consumption at higher pressure and delivered a constant
set pressure to the plant.

85 PSI
SUPPLY

72 PSI (5kg/cm2)
DEMAND

One month after the installation of the Master Air Control, we conducted a secondary
study to ascertain the impact of the controller on the energy consumption. The
saving achieved through this implementation was determined to be 9.3%,
significantly greater than the committed energy saving. The user was also able to
get a better payback period, which now stood at 10 months, as against the earlier
expected 12 months.

Compressed Air Audit at an FMCG Plant in Sri Lanka!

Forbes Marshall Air Efficiency Solutions team conducted an Energy Audit of
Compressed Air System at a Consumer Goods manufacturing plant in Sri Lanka in
August 2014.
Compressed air is one of the most critical utilities in a manufacturing plant and
is mainly used for Instrument Air, Packing & Cleaning. This organization is a
progressive company that is very conscious about energy conservation and takes
several internal initiatives to reduce energy consumption. They engaged us to

FORBES MARSHALL | 45

do an audit to identify further potential for increasing energy efficiency. Since

they were largely satisfied with performance of the generation side, the primary
mandate given to us was to map the air flow requirement in the various plant lines,
while identifying further potential in the demand side.
Major activities involved in air audit were: Power profiling at compressors,
Compressor Efficiency measurement, Pressure Profiling and Mapping, Flow
Profiling, Air Leak Detection and Air Pipeline Network study. After conducting
the audit of the complete system, surprisingly we found that, in addition
to the saving potential in the demand side, there was a huge energy saving
potential on the Generation side as well, which the plant management
wasnt aware of. On the basis of findings, we recommended following solutions:

Replacement of Desiccant Air Dryers with new Refrigerant Dryers.

Air Leak arresting and regular proactive maintenance.
Replacing existing Drain Traps by No-Loss Drain Traps.
Ring Main network was recommended over existing dead end Branched
network. By implementing simple modifications in existing Air Pipeline Network, the problem of user side pressure drop was resolved
with very less effort.
Compressor Pressure Set-points Reduction: Pressure set point reduction
was achieved by modifying piping network, air dryers and installing a demand controller. Installation of a Master Air Control (Demand controller)
was recommended to reduce excess pressurization and excess compressed
air demand in existing system without affecting the plant operations.

FORBES MARSHALL | 46

The total existing annual power cost for compressed air system was 21.8million
LKR/annum (164,000 USD/annum). The total energy saving potential was
up to 19.7%. Savings in terms of cost was 4.3million LKR/annum (32,500 USD/
annum) with a payback period of 4 months only.

Compressed AIR Leak Audit in Refinery!

Forbes Marshall Air Efficiency Solutions team conducted Compressed Air and
Nitrogen Leak survey of Compressed Air System at Oil and Gas Refinery in Andhra
Pradesh, India in January 2015.
Oil refineries are typically large, sprawling industrial complexes with
extensive piping running throughout, carrying streams of fluids between
large chemical processing units. Compressed Air is a very important utility in the
refinery with the network spread over in the whole refinery, and contributes to a
large portion of their energy expenses. It is, therefore, vital for refineries to maintain
their compressed air networks at a high level by conducting audits regularly. As
part of these efforts, this refinery regularly engages experts for conducting leak
audits regularly with extensive efforts. This is a specialized requirement due to the
highly explosive and highly reactive environment in the refinery.
Here, Forbes Marshall conducted a Three-Week extensive Leak Audit with special
purpose Explosion-Proof equipment and will conduct further audits periodically
within a period of 2.5 years. The scope of the audit involved Compressed Air
and Nitrogen Leak Detection, Leak Quantification, Leak Classification and Leak
Tagging. After conducting the Leak audit, the total air loss through leaks was
found to be around 2000 Nm3/Hour which was 9.5% of total generation capacity.
Total loss in terms of cost was Rs. 1.56 Crore/Annum. These leaks will be corrected
with utmost urgency by the refinery maintenance team.

FORBES MARSHALL | 47

Using the Compressed Air Self-Assessment Form!

The Compressed Air Self-Assessment Form has three main sections:
Section A - for recording system and operating data including calculating the
annual running cost.
Section B - for calculating the sources of wastage and the system efficiency
score.
Section C - for verifying that key efficiency items have been checked and
appropriate actions taken.
The following is a guide on how to use each section.
Section A - Compressed Air System Measurements
This section of the form is used to capture system operating data important
to either completing the efficiency scoring in Section B or to making other
recommendations to the business owner. Note: In cases where the plant has two
or more distinct compressed air systems (separate from each other), separate selfassessment forms should be completed for each system.
Items

Data Measured

Explanation

A to D

Compressor
cycling time
measurements

Measurement of compressor loading data during a typical

production period is required to identify the appropriateness
of the compressor to its use, and to calculate the
percentage of air leakage if required.

For Fixed speed

compressors

For a fixed speed compressor, the measurements should

be taken to cover at least two full cycles of loading
and unloading. Record the total length of time that the
compressor runs loaded, the total length of time it runs
unloaded (idles), and the total length of time that it is in
shutdown mode.
Add and record the total duration of the three cycle phases.

For Variable
speed
compressors

For a variable flow compressor either:a) for a period of

approximately 15 minutes, record the average kW loading
of the compressor; or
b) refer to the running records of the compressor and
record its historic average loading
Make a judgment as to the most representative average
loading.

FORBES MARSHALL | 48

Leakage
percentage

Estimate the leakage rate to the best of your abilities

(formulae given below)
Ideally such measurements are made by observing the
compressors for 5 compressor cycles.

Pressure drop
across the
system

Measure the system pressure between the generation and

the final point of use. Compare the pressure reading taken
at the end use tool, with the unload pressure setting of the
compressor.
The difference is the pressure drop across the system (or
system pressure drop).

Pressure setting

Record the reload pressure setting on the compressor

Compressor
capacity

The compressor power in kW should be available from the

compressor or motor data plate

Annual
operating hours

This detail is normally available from the compressor control

panel. Alternatively, calculate from the businesss operating
hours (e.g. 8 hr day x 5 day week x 50 week year = 2000 hrs).

Minimum
pressure
requirement

This is determined by the air pressure required by the air

tools used by the business, but should be confirmed by the
manager running the plant.

Electricity Cost

As provided by the manager of the business. If not available use

a default of Rs. 6.5/kWh the average for a small business.

Off-Load running For screw compressors, the off-load running power

power (as a% of is typically about 30% of the full load power. Unless
capacity)
specificinformation is available use 30% as a default

Off-load
shutdown
time setting

Normally the off-load shutdown time setting is adjustable

either through the digital control menu or the off-load run
timer within the starter cabinet (for non-digital control units).
On some smaller compressors there is a no shutdown
timer and the compressor goes from on-load running to
shutdown. In this case the off-load running to shutdown
time is zero.
At the commencement of off-load running the shutdown
timer commences a count down. If at the end of a set time
(the off-load shutdown time setting) the compressor has
not re-loaded, it will shut down. If the compressor has a
long off-load running time (before shutdown) there might
be excessive energy use.
Comparing the off-load shutdown time setting to the
unload running time may result in a shortening of the time
setting to reduce wasted electricity.

FORBES MARSHALL | 49

Calculating Air Leakage Percentage

1. Timing Method
Start the compressor when there is no operational demand for compressed
air, and allow the system to rise to normal operating pressure and unload.
If there is leakage the compressor will go into a reload/unload cycle.
The load and unload cycle times (when the only demand for air is leakage)
provide the data needed to measure the leakage rate.
Air leakage rate (m3/min) =

Air flow rating (m3/min) x T

(t+T)

Where, for a full load/unload cycle:

Air flow rating = flow rating of the compressor at the operating pressure being
used
T = time compressor is fully loaded
t = time compressor is fully unloaded (idling and shutdown time)
Measuring the times over about five cycles (and checking that cycle times
are consistent during over those cycles) will provide confidence that the only
demand for compressed air is leakage.
2. Pressure Decay Method
This method measures the time taken for the system pressure to decay during a
period when there is no operational demand for compressed air.
It requires the following:
Estimating the volume of the air network (including the receiver) in cubic
metres. The receiver volume should be shown on the cylinder and the rest of
the volume will need to be estimated;
Allowing the compressor to run until the system reaches its operating pressure
and unloads;
Note the reading on the receivers pressure gauge and immediately turn the
compressor off; and
Measure the time in seconds (T) for the pressure on the gauge on drop by 1
bar;
The air leakage rate can then be calculated as:
Air leakage rate (m3/min) = Air network Volume x 60
T

FORBES MARSHALL | 50

Compressed Air Self-Assessment Form!

COMPANY DETAILS

Company Name

Address
SECTION A: COMPRESSED AIR SYSTEM MEASUREMENTS

mandatory input fields

defaults for use if necessary

Operating measurements
Cycle phase time measurements

On-load

sec

Off-load

sec

sec

Total time elapsed (Af+B+C)

0 sec

Leakage estimate

Pressure drop across system

bar

Pressure setting

bar(g)

kW

Shutdown

Static information
Compressor capacity
Annual operating hours

hours

Minimum pressure requirement

bar(g)

Electricity cost

Off-load running power (as a % of capacity)

Off-load shutdown time setting

30 %
sec

Calculations:
Percentage of time on-load

=(Af/D)*100

#DIV/0!

Percentage of time off-load

=(B/D)*100

#DIV/0!

Average load

=H*(X+L*Y)

#DIV/0!

kW

Existing annual usage cost

=Z*I*K

#DIV/0!

per annum

FORBES MARSHALL | 51

SECTION B: WASTAGE AND EFFICIENCY SCORING

Idling wastage

=Y*L*H*I*K/10,000

per annum

Leakage wastage

=E*X*H*I*K/10,000

per annum

System pressure drop

=F*0.07*X*H*I*K/100

per annum

Excess operating pressure

=(G-J-F)*0.07*X*H*I*K/100

per annum

=100*W/T

% (W%)

Sum of energy wastage (sum of above calculated values)

Wastage as percentage of total usage

per annum (W)

Note: Excess operating pressure cost formula does not double count the effect of being able to reduce operating
pressure if system pressure drop is fixed
Assumption: Every 1bar excess operating pressure is equivalent to 7% power wastage
Efficiency Score

=100-W%

Efficiency score to AERS Rating

#DIV/0!

Efficiency Score Range

Rating
0 to 29

30 to 59

60 to 79

80 to 89

90 and over

AERS rating - range from 1 (poor) to 5 (excellent)

SECTION C: CHECKLIST OF ITEMS FROM WHERE IMPROVEMENTS IN COMPRESSED AIR PERFORMANCE MIGHT
BE AVAILABLE
Comments and actions recommended
Item
(Please refer to Annexure 2 for instructions)
Air leakage
Off-load running wastage
System pressure drop
Other excess operating pressure
Compressor intake clear and filter clean
Ventilation ducts on compressor motor
V-belts tension
Condensate drains
Artificial demand identified
Air storage capacity
CER Rating sign off
Self-Assessment conducted by (Utility Manager):

Date:

Self-Assessment accepted by (Technical Head/Plant Head):

Date:

FORBES MARSHALL | 52

Air Audits Customer Information Sheet!

(If you require a visit by our trained engineers to help evaluate the energy saving potential in your plant,
please fill in this information sheet and email it to us, along with the self-assessment form.)

S. No. CUSTOMER INFORMATION

1

NAME:

COMPANY:

ADDRESS:

CITY:

STATE:

PIN CODE:

TELEPHONE:

EMAIL:

GENERAL DATA
9

Are there any issues with your compressed air

network that you are aware of

10

Please explain the 3 most important uses for

compressed air in your plant

Desciption

Pressure Required

Use # 1
Use # 2
Use # 3
11

Any areas in your plant that experiences

pressure problems? Please explain.

12

What is the pressure going into the Main

Header

13

What is the pressure for typical operation in

the plant?

14

Have compressor set points been raised to try

and compensate for low pressure at end use
applications?

15

Have compressor set points been raised to try

and compensate for low pressure at end use
applications?

FORBES MARSHALL | 53

16

COMPRESSOR
INFORMATION

S.
No

Make

Type

KW

CFM
Capacity

Loading
Pressure

Unloading
Pressure

Operating
Status

1
2
3
4
5
6
7
8
If you have more compressors, please mention the details for the rest of the compressors in a separate page
17

How many compressors do you operate during work

production?

18

How many off shift?

19

Total CFM Demand

19

Nos. of Units to be Audited

20

If we perform a compressor air delivery test or a plant

air leak test, this work may have be done off shift.
The system MAY require to be isolated and off line
(winterrupted or closed off) for a brief period of
time. Is this possible to do?

PLANT INFORMATION

21

Number of operating hours per year

22

What is your KWH rate?

23

Plant Pipe Size

Main

inches

Auxiliary

inches

To Equipment

inches

FORBES MARSHALL | 54

Email : [email protected] and [email protected]

Forbes Marshall Pvt. Ltd. (CIN NO: U28996PN1985PTC037806)

DOC # FMAES/0315/2101/V2.R0