Cement Manufacturers Association (CMA)

34 Leaks There were multiple leaks throughout the facility, these leaks were identified and quantified using an ultrasonic leak detector. The leaks identified were mainly concentrated at joints, couplings, valves, instrumentation, etc along the pipelines and near end use equipment’s. In addition to that compressed air is being inappropriately used at many locations at the plant for cleaning purposes. The most common areas of leaks are as follows. • Couplings, hoses, tubes, and fittings. • Disconnects. complete the seal may be missing. • Filters, regulators, and lubricators (FRLs). Low first-cost improperly installed FRLs often leak. • •Open condensate traps. Improperly operating solenoids. • Pipe joints. Missed welds in line. • Point in end use devices. Problems associated with air leaks. • Drop in system pressure. Power and installation • For every horsepower, a compressor delivers 4-5 CFM (m3/hr), at 100 psi (7 bar) pressure. • A 50 HP air compressor can produce up • Compressed air-based equipment to work less efficiently. • Reduction in lifetime of compressed air equipment. • Increased running time leading to increased energy consumption and costs. • Additional maintenance requirements due to unplanned downtime of equipment. Fix the identified compressed air leaks Compressed air leak audit was conducted at the plant to identify leaks along the pipelines of compressed air network, the identified leaks were tagged immediately at site with yellow and red tags, red tags indicating necessity to repair immediately. There were many leaks identified. Refer section 5.3.1 for more details. Fix all the identified leaks by replacing damaged components and tightening of other components to arrest air leakages mostly at joints. Description Units Values No of leak points Identified nos 234 Leakage detected LPM 4862 CFM 172 Average Specific Energy Consumption kW/CFM 0.17 Annual Operating Hours hrs 7440 Estimated Energy Savings kWh 210969 Actual Cost Savings Rs.(lakhs) 18.6 Investment for repairs Rs.(lakhs) 05 Simple Payback period months 3.2 RULES OF THUMB to 45 litres of water per day (with only 8 running hours daily). • Air receivers should be sized about 15 litres capacity for each CFM of 3 compressor