LAKSHMI MACHINE WORKS
JoulePAYS for Compressed Air Optimization
Facility Type
Industrial- Other
Location
Coimbatore
Start Date
Aug-2021
Project Tenure
5 Years
19% energy efficiency delivered till October 2022, equivalent to INR 4 mn yearly cost savings
Design Interventions
- Thorough compressed air system assessment to establish compressed air generation and utilization profiles
- Segregation of high pressure and low-pressure operating equipment and timelines
- Benchmarking individual equipment and overall system efficiency
- Modification of existing pipelines to minimize losses during nonoperational times
Equipment Interventions
- Old inefficient compressors replaced with 2 new compressors (110 kW VFD and 160 kW fixed speed)
- New hoses for cleaning points and pneumatic tools
- Zero loss auto drain valves for moisture control
- Installation of air flow meters, pressure sensors, vibration sensors, energy meters, temperature and humidity sensors and other instrumentation
Operations Interventions
- Continuous online monitoring of equipment and system level performance with DeJoule
- Monthly compressed air leakage identification and reduction (230+ leaks arrested)
- Automated compressor operations with dynamic staging to optimize loading and unloading percentages
- Dynamic pressure set point optimization with changing uses
- Data-driven maintenance to optimize compressor efficiency
Project Output
Efficiency improvement in kWh/ton
Yearly cost savings of INR 4 mn