Air Compressor Performance Monitoring

Purpose: Compressor Intake Air Temp. wrt Ambient Temp.

Compressor No.

Air Compressor
Location

Ambient Temp.

Temp at AIR
suction point

1
2
3
4
5
6
7

Boiler
Boiler
Boiler
Boiler
Boiler
Boiler
Boiler

38
38
38
38
38
38
38

38
39.5
38.5
46
46
43
43

Amp.

NW
273
220
280
180

Volt

NW
425
425
425
425

Present
Power
Drawn

Temp Air
Difference

Extra Power
Consumption than
normal %

Corrected Power

KW Saving

191
154
196
126

8
8
5
5

2
2
1.25
1.25

187.08938
150.768
193.35507
124.29969

3.82
3.08
2.45
1.57
total

IA-1
IA-2
IA-3
IA-4
IA-5
IA-6
IA-7
PA-1
PA-2

Power H
Power H
Power H
Power H
Power H
Power H
Power H
Power H
Power H

34
34
34
36.5
36.5
35
35
35
35

38
38
38
39
40
40
40
42
41

NW
NW
NW
186
198
207
NW
28
27

NW
NW
NW
425
425
425
NW
6600
6600

130
138
145

2.5
3.5
5

0.625
0.875
1.25

129.25594
137.24888
142.94464

0.81
1.21
1.81

304
293

7
6

1.75
1.5

298.7487
288.81213

5.32
4.40
total

TOTAL SAVINGS

Per Annum
Saving Lacs.

1.6631864
1.3402968
1.0661452
0.685379
4.76

0.3541125
0.5277419
0.7881859
2.317925
1.915836
5.021947
9.78

Measures for Efficienct Operation of Air Compressor

1
2
3
4
5
6
7
8
10

Cool air intake across the compressor, Every 4 C rise in inlet air temperature results in a h
Dust Free air intake through air filter. Provided pressure drop should be lesser. Large duct si
inadequate cooling in after cooler allow warm & humid air into the receiver which causes m
which in turn lead to increased corrosion pressure drop and leakages in piping.
Loading and unloading to be optimize because a compressor consume more power at highe
a reduction in the delivery pressure by 1 bar in a compressor would reduce the power cons
A compressor with low unload losses can be put in cycle ( load - unload ) mode.
segregate low pressure and high pressure requiring units seprataely.reducing pressure is a
High line losses lead to further waste of power. Recommneded is 0.3 bar in main header &
Avoiding leaks in compressed air system like in air receiver, relief valve, pipe, joints shutoff
pipe should be given a fall of not less than 1 m in 100 m in the direction of flow and 30 m b

ompressor

emperature results in a higher energy consumption by 1 % to achieve Eq Power

d be lesser. Large duct size with least bend.
receiver which causes more condensation in air receiver and distribution lines
es in piping.
ume more power at higher pressure. Ans also the volumetric efficiency of compressor is also less at higher deliv
d reduce the power consumption by 6 to 10 %
nload ) mode.
ly.reducing pressure is a waste of energy.
.3 bar in main header & 0.5 bar in distribution.
valve, pipe, joints shutoff valve etc
ection of flow and 30 m between 2 drainage points.

also less at higher delivery pressure.

Compressor No.

Air Compressor
Location

1
2
3
4
5
6
7

Boiler
Boiler
Boiler
Boiler
Boiler
Boiler
Boiler

IA-1
IA-2
IA-3
IA-4
IA-5
IA-6
IA-7
PA-1
PA-2

Power H
Power H
Power H
Power H
Power H
Power H
Power H
Power H
Power H

Type

Location
IJT Area
IJT Area
IJT Area
CT3 Area
CT3 Area
Slop2 area
Slop2 area

Design Cap. Design

Pressure

Loading
Press

Unloading
Press

Loading
Time

Unloading
Time

Main Users
Connected
with a
common
header from
IJT to New
Slop