CALCULATING % LEAKAGES IN YOUR PLANT | Leaks Repair | Compressed Air System Energy Audit

Whereas it poses a great challenge to estimate the sum of all leakages at one point of time in a plant, it is a simple calculation which gives one an excellent ball park figure as to how much 'trouble' the compressed air systems is in. To calculate leakage in a plant simply pressurize the compressor when the plant is shut down and no machines or equipments are operating. Then record the load and no load time of the compressor for a set period of time which could be anywhere between 30 minutes to an hour. The % leakage of the compressed air system is simply the division of the on load time divided by the total time the measurement has been taken. For e.g. If a reading has been taken for 30 minutes...and the total number of minutes the compressor was working was 7.5 minutes then the percent leakage of the plant is 7.5/30 = 25%. Advance Energy Solutions|Leaks Repair|About Us Leaks Repair offers a wide range of Compressed Air Energy Management Solutions & Industrial Energy Savi…

MINIMIZE COMPRESSED AIR LEAKS | Leaks Repair | Compressed Air Audit Services

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 productionExcess compressor capacity, resulting in higher than necessary costsDecreased service life and increased maintenance of supply equipment (including the compressor package) due to unnecessary cycling and increased run time.

Although leaks can occur in any part of the system, the most common problem areas are: couplings, hoses, tubes, fittings, pipe joints, quick disconnects, FRLs (filter, regulator, and 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. L…



Excerpts from Pascal Director VP INSTRUMENTS - Sharing the VP Vision Ever tried to configure a plant wide energy management system yourself ? The answer is probably no. Because most energy management platforms and SCADA systems are too complicated. You need to call an IT expert of consultant at $$$ per hour to add a sensor, configure an alarm or create a simple report. With VPVision, you are back in control. Thanks to the user friendly web interface, and transparent software architecture, you can add, remove, modify sensors yourself. Anywhere, at any time. Within a few mouse clicks, or using your tablet, you can build a system with our VPFlowScope 3 in one compressed air flowmeters, and kW meters. But you can also expand towards water, steam and natural gas. After installation of the sensor hardware, you can easily add the devices via the VPVision configuration panel.

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EFFECTIVE ENERGY MEASURES OF RUNNING PLANT | Leaks Repair | Compressed Air Leakage Management

The total investment year on year on a compressed air system supply is highly dependent upon the periodic maintenance done on the system. A running plant has many avenues to spend from their maintenance budget annually to see where they can save on breakdowns, expensive repairs and other production related losses connected to these issues. Whereas in the Short term, optimization of the compressed air system save substantial costs but, it does not give a substantiated saving on the total amount of air which is being utilized in the plant. Motor Control and Heat Recovery do also give tangible savings but over a longer period of time which can be spread over a period of two to three years where a planned approach to the same yields substantiated benefits. When calculating the Return on Investment ROI on the measures taken to save energy in the plant it makes complete sense to invest in THE LMS NORDIC with a proper planning for leakage identification, rectification and reassessment of th…

MONITORING COMPRESSOR PERFORMANCE | Leaks Repair | Air Compressor Energy Audit

Monitoring Compressor Performance with the VP Flow Terminal

The VPFlowTerminal enables you to measure flow, pressure, temperature with one single VPFlowScope. In addition, the VPFlowTerminal offers 4 analog input channels, which can be used for logging of any 4..20 mA based sensor. In this example, we will show you how to use the VPFlowTerminal to monitor compressor performance. Please note that this is not intended as an official compressor test, but you can use the data to track changes in performance, or to create a “practical” efficiency curve of the compressor when installed in the field. It is a great tool to get more insight in the real behavior of your system. This application note is also not intended to be a course on how to work with spreadsheet programs, so basic knowledge of a spreadsheet program is recommended. Compressor efficiency or specific energySensorsConfiguration of the VPFlowTerminalCurrent to power calculationSetting the logging intervalData analysis

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Leaks cost big money, compressed air systems are widely used throughout the industries and if not maintained and audited on a regular basis, are bound to have leakages which can contribute significantly to the facilities cost of energy. Thus, it is essential to address this problem through the development of a comprehensive leak management program.These cost saving radiate out in the form of possible cost reductions of 25-50% and hence result in higher profit margins for the company. Companies presently starting at Level 1 as seen in the image, are unaware of their current compressed air leakages and, with a proper leakage program in place can reach Level 4 eventually. The objective of a leakage management program is to to cut down the leakages and energy wastages in a plant to under 5%. Leakages supervene when the compressed air systems are not maintained the way it is needed to prevent wastage of energy. The factors i…

SIX KEY REASONS WHY ALUMINUM PIPING | Leaks Repair | Compressed Air Energy Audit

In the past decades of Engineering Industry, traditional piping solutions like GI, Mild Steel and Stainless Steel piping have been used to convey compressed air and other industrial gases. But, as these piping systems came with their own set of problems, users tries to experiment with alternate materials. Aluminum seemed to solve most of the problems.

However, joining Aluminum to Aluminum has always remained a challenge due to it’s inherent properties and stubbornness to bond only after having special welding techniques. With the advent of the push fit technology, Aluminum Piping gained popularity. Black iron and galvanized steel pipe are two common types of pipe used for compressed air systems. More than 60% to 70% of all compressed air systems installed today use black iron or galvanized pipe, due to a variety of factors : Contractors are familiar with these materials.

Material costs are low.The pipe and compressed air system fittings are readily available.Steel pipe is rated for high…