An approach to optimising compressed air systems in production operations

A low-cost, non-intrusive method of quantifying the energy consumed by compressed air systems (CASs) and lost through system leaks is described, with various means of minimising energy consumption presented. Case studies across different industrial facility types are examined where the approach used in quantifying energy losses due to system leaks has been implemented. Monitoring across 5 sites identified circa 500,000 kWh of waste energy due to leaks of which 30–60% can be saved. The approach has reduced waste electrical consumption by 60% on one site. Non-energy-related benefits arising from awareness of CAS losses are described. The proposed approach effectively illustrates the benefits of CAS energy analysis in a manner which can be quickly and easily implemented using off-the-shelf energy monitoring and data-logging equipment. The methodology can be regularly applied to provide continual monitoring and management of the optimal state of an industrial facilities CAS.