Air compressors account for a significant amount of electricity used in Indian industries. They are used in a variety of industries to process requirements, operate pneumatic tools and equipment to meet instrumentation needs. Only 10-30% of energy reaches the point of end-use and a balance of 70-90% of energy is converted to unusable heat energy and to a lesser extent is lost in the form of friction, misuse and noise. The figure below gives an idea of the functioning of the compressor.
One of our customers in Pune had installed two air compressors to meet his air requirement in the plant. With ENERLLY data analysis, it was observed that both the compressors were not fully loaded and operating at 60% load only. In a compressor, a lot of energy is lost in the form of heat outside to surroundings. Inappropriate pressure setting and leakages in line lead to maximum losses anywhere in any industry. Improper training to the workforce for utilizing compressed air also adds to the losses. The client was losing about Rs. 12000 per month because of such wrong practices. Enerlly data analytics software monitors data on energy consumption and several other parameters like a run house, loading %, active power, demand, GHG emission on time to time basis.
Compressed air requirement data analytics showed that only one air compressor would meet the demand in the plant. The compressor pressure setting optimization and identification of leakages in line saves energy without much investment. The leakage point should be identified early and repaired as soon as possible to avoid losses. Training the workforce on utilizing the air as and when required adds to savings. With such improved practices client was able to save Rs. 40000 monthly. So this is how data monitoring and analysis helps the end-user achieve savings and energy efficiency.
About Us: Enerlly is an organization rooted in industrial automation that deploys Internet-of-Things (IoT) based controllers and online platforms to create sustainable eco-conscious brands through real-time energy monitoring, energy data analytics, and consultancy Energy Auditors.