admin's blog

Stagewise Energy Savings for a Compressed Air System

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 t​o address​ this problem​ through the development of a ​comprehensive ​leak management program.These cost saving radiate out in the form of possible cost reduction​s​ 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 wastage​s​ 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 include​ :-

​ ​1. ​non establishment of cost​ of leakages​,

​2. no measuring and monitoring of the demand and supply,​ ​

​3. ​poor optimization,

​4. ​non established​ norms for​ air quality,

​5. ​poor or no leakage management which ​can ​critically ​a​ffect the system as a whole and may result ​ in​ an​ increase in cost​s.

Six Reasons Why Aluminum Piping is the Ultimate Energy Saving Solution for Compressed Air Systems

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. 1. Material costs are low. 2. The pipe and compressed air system fittings are readily available. 3. Steel pipe is rated for high pressure. There are, however, six key reasons why aluminum piping is a superior material to use for most compressed air installations today, each of which addresses a key disadvantage to traditional pipe systems.

Effective Energy Measures of Running Plant

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.

For immediate measures a proper leakage management program like the LMS NORDIC set in place saves a lot of money and improves on the system pressures resulting in improvement in manufacturing efficiencies and greater outputs as compared to what was the state of the plant before the LMS was put in place.

Findings range to about almost 35 to 40% savings in compressed air costs related to power consumption which is very high as compared to other measures which could be adopted to realize immediate savings from any other resource being consumed by he plant for its production.

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 the total savings. A program which, when implemented annually results in major savings year on year with excellent performance characteristics and minimum break downs of critical equipment in the plant, improving bottom lines and reducing strain on the management to cut corners the to poor production outputs.

Monitoring Compressor Performance with the VPFlowTerminal

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.


Aluminum piping for compressed air is a new concept which is basically using Push In fittings to join aluminum pipe. It takes a very limited amount of time and no tools are required for the same. It can be used for pressures upto 17 bar and because of the fact that all fittings and pipes are made in aluminum there is a good durability of the system and the air system remains corrosion free and leakage free for years. Owing to the beautiful system design, PNEUMSYS aluminum piping ensures that the possibility of very easy to re-open and again assemble the fittings from the pipe. As a result of this mobility is increased and it becomes very easy to dismantle an entire pneumatic system and relocate it or modify it as per the user's requirements.

Minimize Compressed Air Leaks

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