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Energy lost on Air leaks

How do you manage your most expensive Utility in your Plant ?
Do you know what constitutes a major pie in your energy consumption chart ?

Air compressors play an important role in any facility, and their energy consumption can make up a significant percentage of total energy use. Since compressed air is often the most expensive utility, operating costs can be significant. This is why, in recent years, increasing numbers of plants and facilities have started taking steps to reduce the amount of energy used by air compressors.
What Smart Plant Operators do to reduce the energy used by air compressors?
1. Create and manage an air compressor operating schedule.
Identify idle periods when the compressor can be shutdown. Automatic data logging and analysis can help a scientific approach.
2. Fix existing system leaks. Large leaks will be audible, while smaller leaks will need to be identified by ultrasonic leak detection technology. A periodic Air Audit will help.
3. Drawing cool air from outside the facility rather than using hot air from inside can reduce the air compressor’s energy consumption by 3%. 
4. Cleaning filters and reducing supply resistance to the air compressor to below 200mmWC can reduce energy consumption by 1%.
5. Optimize air system condensate drainage with air traps and separators designed to remove moisture and conserve air.
Removing moisture to protect equipment and products is a critical function in compressed air systems. Remember Timer-based systems are not configured to match moisture loads during different seasons.
6. And Finally, Fix the Leaks ..Save Energy
Using the characteristics of Ultrasound, locating leaks is fast and easy to do so because of:
Directionality of sound waves makes locating the source easy
Intensity of signal: the closer you get, the more sound you detect
Fixed frequency, making it effective to locate even in a loud factory environment!
As any gas (air, oxygen, nitrogen, etc.) passes through a leak orifice, it generates a turbulent flow with detectable high frequency components.
By scanning the test area with an Ultraprobe, a leak can be heard through the headset as a rushing sound or noted on the display/meter. The closer the instrument is to the leak, the louder the rushing sound and the higher the reading.
Should ambient noise be a problem, a rubber focusing probe may be used to narrow the instrument’s reception field and to shield it from conflicting ultrasounds.
In addition, Frequency Tuning dramatically reduces background noise interference to provide ease of ultrasonic leak detection as never before experienced. It is estimated that 30% Energy used on Compressed Air is lost to leaks.
There are software available to  calculate the losses per leak in terms of money lost. It can also provide information on gases that contribute to the carbon footprint.
Do you want to play smart in your organisation ?

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