GOOD PRACTICE CASE STUDY 346

Compressed air savings through

leakage reduction and the use of
high efficiency air nozzles
Van Leer (UK) Limited

■ 25% energy cost savings

■ Nine month payback period

■ Potential for greater savings

■ Very simple actions

GOOD PRACTICE CASE STUDY 346

BEST PRACTICE
PROGRAMME
 COMPRESSED AIR SAVINGS THROUGH LEAKAGE REDUCTION

IDENTIFYING THE PROBLEM

Fig 1 The effect of the leakage reduction programme at Van Leer (UK) Limited BACKGROUND
180 15 Van Leer (UK) Limited manufactures steel drums at
its Robinson Works in Hull. The drums range in
14 size from 10 to 60 litres and are sold for use in the
160 distribution of paints, oils and other industrial
13
products. Compressed air is used throughout the

Annual cost of leakage (£000/year)

1st leakage reduction exercise
12 plant but the main uses are:
140
11
leakage (l/s)

■ sheet steel stack separation prior to

120 10 press feeding;

9 ■ product leak testing;

2nd leakage reduction exercise
100
8
■ press operation;

80
60
28 30 32 34 36 38 40 42 44 46 48 50 52 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34
Actual leakage
Reducing leakage by
tightening a compression
union on an air filter
Week number 1994/1995
Estimated leakage if no
repairs carried out
7
■ paint spraying;
6
■ seam welding.
5
The air systems on these machines include
numerous hoses and other fittings which are prone
Leakage measurement point
to leak if not maintained. Air is distributed
throughout the plant by four compressors with a
total supply capacity of 609 l/s (1,290 scfm).
In July 1994 the company commissioned a survey of
its compressed air system, which identified two
major problems. Firstly, 36% of the compressed air
was being lost through 90 different leaks, and
secondly, the nozzles used required over twice as
much compressed air than more air efficient models.

Van Leer decided to address both of these

problems by:

■ initiating a leakage reduction programme

aimed at eliminating most of the identified
leaks (Fig 1);

■ replacing a number of the old nozzles with air

efficient models.

The project was monitored independently by: The Dyer Warner Partnership. Tel: 0116 267 7017
Specialist compressed air consultant: Air Technology Ltd. Tel: 01509 264301
The air efficient nozzles were supplied by: Economatics (Industrial) Ltd. Tel: 0114 281 3344
There are other suppliers of similar services and energy efficient equipment in the market. Please consult
your supply directories or contact ETSU who may be able to provide you with more details on request.

Leakage source - compression
union on moving pipes
COMPRESSED AIR SAVINGS THROUGH LEAKAGE REDUCTION
REDUCING COMPRESSED AIR DEMAND
LEAKAGE REDUCTION PROGRAMME
Leaks in a compressed air system can occur for
various reasons.
LEAKING PIPE UNIONS
On some machines, flexible pipes carry compressed
air from static to moving parts of the machinery.
Compression type joints at the end of the pipes
experience stress with each movement and
eventually begin to leak. In many cases, simply
tightening the union eliminates the leak.
Alternatively, the compression olive at the ends of
the pipe may need to be replaced before tightening.
LEAKING PNEUMATIC CYLINDERS
Sealing rings within pneumatic cylinders become
worn with use and begin to leak. If not replaced
periodically, leakage will increase.
LEAKING FILTER AND LUBRICATOR BOWLS
The gaskets on filter or lubricating bowls can
become damaged during maintenance work and will
subsequently leak. When this occurs, simply
tightening the bowls can often eliminate the leak.
For larger leaks a replacement gasket may be needed.
LEAKING SOLENOID VALVES
The sealing diaphragm within solenoid valves can
perforate. When this happens the valve is not able
to shut off effectively. Often the easiest repair is to
renew the whole valve, although with larger valves
it is possible to just replace the diaphragm.
FLEXIBLE HOSES
Even in normal use, flexible hoses can develop
leaks either at the end fittings or due to hose splits.
Damaged flexible hoses should be replaced.
New air efficient nozzle on a de-coiling machine
AIR EFFICIENT NOZZLES
At Van Leer Limited the separation of blanks from
sheet steel stacks was originally carried out using
copper pipes flattened at the end to form a crude
nozzle. A number of these have been replaced with
air efficient models.
Air efficient nozzles use less compressed air by
projecting a precise jet of air at the task. Nozzles
have been developed by a number of manufacturers
to give specific air jet patterns for different
applications. For sheet separation, a broad, knife-
like jet is required.
Van Leer installed three air efficient nozzles for
stack separation. There are over 40 air nozzles in
the factory which are being investigated in turn to
see if there is any benefit in replacing them with air
efficient nozzles.
 COMPRESSED AIR SAVINGS THROUGH LEAKAGE REDUCTION

RESULTS

MONITORING
Monitoring was undertaken to verify the energy Table 1 Nozzle specifications
savings achieved by the leakage reduction exercise Operating pressure Air consumption
and the air efficient nozzles. This consisted of:
Bar g psig I/s scfm
■ measuring system leakage on five dates over a Copper pipe nozzle 4.1 60 9.1 19.2
13-month period to assess the effect of the Air efficient nozzle 1.4 20 2.9 6.1
leakage reduction exercise;
Saving 6.2 13.1

■ measuring the air used by both the old high

pressure nozzles and the new air efficient
40
nozzles while performing the same task. 38.4

35
31.1
The results of the leakage monitoring programme
30
(Fig 1) show a steady worsening of the leakage rate
Leakage rate (l/s)

during periods when no repair work was carried out. 25 23.8

22.4
18.9
20
17.7
The leakage reduction exercise, implemented over
15
two weekends in February 1995, achieved a saving 12.3
10.4
of 67.5 l/s (143 scfm). Although the leakage 10
7.7 7.5
increased steadily from the point the repairs were 4.9 4.6
5
made, the graph (Fig 1) shows how the leakage
0
would have increased anyway at the same rate, Filters and Connections Solenoid Internal Split hoses Other
irrespective of whether the work had been carried regulators valves machine
leaks
out or not. Leak saving exercises must be carried
out periodically if full benefits are to be maintained. Before leak reduction exercise After leak reduction exercise

The reduction in compressed air usage achieved by
installing air efficient nozzles was calculated by
measuring the air flow to one of the old high
pressure nozzles, and comparing it to one of the
new air efficient nozzles in the same application.
The results in Table 1 show that the new nozzle
reduces air consumption by 68%.
air. Fig 2 shows the sources of leakage before and Fig 2 Sources of leakage
after the leakage reduction exercise. before and after the leakage
reduction exercise
The leakage survey cost £1,700, and a further £2,186
(including replacement parts and labour) was spent
on remedial work. With savings of £5,676/year, this
leakage reduction programme achieved a payback
period of nine months (Table 2).

ECONOMICS The air efficient nozzles were installed on machines

Based on 1994 data, Van Leer Limited uses 179
kWh to produce 1,000 m3 of compressed air, at a
cost of £5.37/1,000m3. The leakage reduction
exercise resulted in annual energy savings of
189,200 kWh worth £5,676/year. This represents a
25% saving on the cost of providing compressed
which operate for approximately 1,000 hours/year.
The reduction of 6.2 l/s from each nozzle saves just
under 4,000 kWh/year worth £120/year. The three
nozzles, installed at a total cost of £105, save
12,000 kWh/year worth £360 giving a payback
period of four months (Table 2).

Table 2 Payback period

Investment Annual Payback
cost Savings
Leakage reduction £3,886 £5676 9 months
Air efficient nozzles £105 £360 4 months
 HOST ORGANISATION

Compressed air is an important service used by the majority of the processes within
our factory. Most of our newer equipment uses extensive pneumatic controls, and the
system has to operate efficiently with little or no pressure fluctuation. There are also
numerous general purpose uses. The compressed air system extends throughout
the factory and with so much equipment using compressed air, leakage
is likely to be a problem.

The survey we commissioned in July 1994 highlighted the cost of leakage, and we were
determined to take rigorous action to reduce it. The monitoring carried out for this
case study confirms that our efforts have been very worthwhile. The expenditure we
made in February 1995 was recovered before the end of the year.

The air efficient nozzles are another success. The old copper pipe nozzles worked
reliably and gave us little cause for concern. However, the survey showed that a
significant saving was possible with air efficient nozzles. The monitoring has
confirmed the savings and it is our intention to replace other nozzles throughout the
factory with air efficient models.

Since the survey was carried out, extensive investment in production equipment has
meant a large increase in compressed air demand, and so the lessons learned in 1995
have become even more valuable.

Mr R A Sisson, Factory Engineer, Van Leer (UK) Limited

VAN LEER (UK) Limited

Van Leer (UK) Limited, Hull, is one of four UK steel drum manufacturing sites of the Royal Packaging
Industries Van Leer BV Group of the Netherlands. The Group holding company is owned by the Van
Leer Group Foundation, which uses its funds to support the Bernard Van Leer Foundation. This
foundation runs projects to benefit socially and culturally disadvantaged children, primarily in
countries where a Van Leer company is established.
 COMPRESSED AIR SAVINGS THROUGH LEAKAGE REDUCTION

CONCLUSIONS

The implementation of a leak reduction
programme and the installation of air efficient
nozzles has reduced Van Leer's annual electricity
consumption by 201,200 kWh, worth £6,036/year.
This gives a payback period of less than nine
months on the investment cost of £3,886.
Ongoing work to fit more air efficient nozzles and
further reduce leakage is expected to make
additional savings of about £4,000/year.
substantial purchasing power. Other users, paying
a higher price for electricity could achieve even
greater cost savings. In addition, savings will
increase pro-rata for higher hours of operation. For
example, had the air efficient nozzles been fitted to
a machine operating for 4,350 hours/year, which is
typical of other equipment, the savings would have
been over four times greater, giving a payback
period of less than a month.

Van Leer can negotiate

favourable electricity tariffs as
it is a large electricity user and
part of a group with

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© CROWN COPYRIGHT FIRST PRINTED JANUARY 1997
REPRINTED JULY 1999