Air leaks causing significant power consumption

Air leaks causing significant power consumption

Air leaks causing significant power consumption

Leaks are a significant source of wasted energy in a compressed air system, often wasting as much as 20%-30% of the compressor’s output. Compressed air leaks can also contribute to problems with system operations, including:

  • Fluctuating system pressure, which can cause air tools and other air-operated equipment to function less efficiently, possibly affecting production

  • Although leaks can occur in any part of the system, the most common problem areas are couplings, hoses, tubes, fittings, pipe joints, quick disconnects, filter, regulator, lubricator, condensate traps, valves, flanges, packings, thread sealants, and point-of-use devices. Leakage rates are a function of the supply pressure in an uncontrolled system and increase with higher system pressures. Leakage rates identified in cubic feet per minute (cfm) are also proportional to the square of the orifice diameter

  • If air leakage size is 1.0mm then the cost of air leakage per year at 8000hrs / 7bar pressure is Rs,20,000 / year. ( Rs 5/KWH)

  • Fixing leaks once is not enough. Conduct an Air audit program into operations at your facility with help of air compressor experts. It should include identification and tagging, tracking, repair, verification, and employee involvement. Set a reasonable target for cost-effective leak reduction 5%-10% of the total system flow is typical for industrial facilities

  • Once leaks are repaired, re-evaluate your compressed air system supply. Work with a compressed air systems specialist to adjust compressor controls and ensure leak-free operations to conserve unproductive power consumption

  • Periodic Air audit program helps to reduce significant power consumption. Connect with MRO Air compressor experts for more details

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