Slash Your Energy Bill

The Hows & Whys of saving Watts in... Air Compressor System

Up to 40% energy can be saved by minimizing air leakages


air compressor

Compressor room

  • Locate the air compressor or your compressor room close to the point(s) of use.
  • Make sure your compressor room is kept clean, dust-free and cool. You can save up to 3% of the energy used by your compressors!
  • Do not expose compressors to sunlight. Also, isolate the compressors from other heat-producing equipment. Provide adequate ventilation.

Piping system

  • Always install overhead compressed air pipelines. If you bury pipelines, you cannot spot leakages. Also, buried pipelines are difficult to repair or replace.
  • Install low-friction pipelines to minimize pressure losses.
  • Install separate lines for high pressure and low pressure.
  • Take out branch lines from the top to avoid moisture carry-over.
  • Avoid unnecessary bends and turns in the distribution network, as these will lead to pressure losses.
  • Install ring main loop holder in distribution network, to minimize pressure loss.
  • Install moisture separators to remove moisture from the air before it enters pneumatic equipment. Moisture separators may not be required if you have installed an air dryer.

Operation & Maintenance

  • Use compressed air only when necessary. Keep the valves closed when not in use.
  • Generate compressed air close to the required end-use pressure—because energy is wasted by compressing air to higher pressure than required! Maintain the pressure at not more than 0.5 kg/cm2 above the maximum requirement. Possible energy savings: 3–5%.
  • Use dedicated air compressors to meet exclusive high or low pressure demands.
  • For very low air pressure requirements, use nozzle-type spray guns.
  • Use air blowers for high-volume, low-pressure compressed air applications such as to clean up mist or dust.
  • Use air receiver to accommodate large volume of intermittent loads.
  • Check for leakages—through joints, valves and bends. Conduct leakage test on a regular basis. Up to 40% energy can be saved by minimizing leakages.
  • Clean the air filters periodically to ensure clean air intake. Accumulation of dirt increases the system resistance—and hence, energy consumption—lowering the efficiency of the compressor.

General

  • Do you have fluctuating loads? If so, use variable frequency drives (VFDs) to save 10–40% energy. You may use one invertor-type air compressor to meet the variable load requirements, and the other compressors to meet base load.
  • Invest in an energy efficient air compressor—because energy accounts for 75% of its life cycle cost while its capital cost (upfront investment) accounts for just 15%!
  • Compressed air means energy and money! Use it wisely.

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Secretary - SAMEEEKSHA, Industrial Energy Efficiency Division,
TERI, Darbari Seth Block, IHC Complex, Lodhi Road, New Delhi 110 003, India
Tel: +91 11 2468 2100, 2468 2111 | Email: sachink@teri.res.in