REPORT ON

Compressed Air, Natural Gas & Steam

Leak Audit
USING

ULTRASOUND TECHNOLOGY
(Report No. MTSPL/13/2023-24 dated 14 July 20)

Client details:-

GRP Pvt. Ltd.,

GIDC Panoli, Panoli, Gujrat
 LIST OF CONTENTS

(1) Introduction (Page-2)

(2) Executive Summary (Page-3)
(3) Summary of Report (Page-4)
(4) Appendix – Leak Report

Page 1 of 4
(A) Introduction: -An Ultrasound Technology based Compressed Air Leak, Natural Gas leak,
Steam leak Audit was undertaken on 5th July 2023 at GRP Pvt. Ltd.
GRP Pvt. Ltd. is a leading manufacturing company of recycling rubber and reusing rubber for new
manufacturing in India. The brief details of the exercise are as follows: -

Organization GRP Pvt. Ltd, GIDC Ankleshwar, Gujrat

Plant Representative Mr. Pragnesh Patel, Mr. Mayank Modi
ICICI Lombard GIC Ltd. Chirag Jaju
Representative
Condition MonitoringInspectors Mr. Ajay Yelve

Focus areas during inspection were Compressed Air Lines of Compressor Room, Transmission
lines between Compressor Room and Production Area, all external distribution system Air Lines
and all internal Pneumatic Circuits within the machines, Natural gas Incomer, Transmission lines
between Natural gas Incomer and Production Area, all external distribution system Natural gas
Incomer.

Objective: - The main objectives of this exercise was to detect all minor and major leaks in
Compressed Air System to find energy losses due to these leaks so that a strategic action plancan
be initiated to enhance plant’s Pneumatic System Hygiene, operational availability, and overall
productivity.

High Voltage Electrical Asset were also inspected to detect presence of any Partial Discharge
(PD) related problems.

(B) Expected benefits: - All the leaking points were identified and documented. Plugging
these leaks will result in monetary savings, operational excellence, and improvement in plant
hygiene. Rectification of PD related problems will improve the reliability of High Voltage Electrical
assets resulting in safe operation and seamless production.

(C) Technology Used: - Air- Borne Ultrasound Technology

(D) Equipment Used: - Sonaphone – III (Make: SONOTEC, Germany)

(2) Executive Summary: -

(A) Jobs Undertaken: Leak detection using Ultrasound Technology for Energy Saving by
findingleaks in Compressed Air Systems, Natural Gas Lines, Steam line. These leaks, being very
small in intensity but large in numbers,could not be traced normally in noisy and activity laden shop
floors.

Page 2 of 4
(B) Results of Inspection: Following points detected during the inspection: -

(i) One leak in Natural Gas Line near Boiler No.2

(ii) One steam leak in Autoclave Steam inlet pipe
(iii) Partial Discharge in Transformer No.1 HT side connectors, R & Y Phases.

(C) Expected monitory savings post rectification of these leaks is about ₹33,375 per annum. A
detailed report indicating location, picture and extent of leaks is attached at Appendix A of this
report. As a general industry standard, an annual saving between 20% to 30% can be achieved by a
complete rectification of identified leaks. Savings will result fromlesser running hours of compressors
for catering same requirement of shop floor, thus reducing overall Compressor’s power consumption
and allied maintenance work.

Calculation basis for Estimated Losses and Potential Savings

Total Leak Cost Total cost of Leak
Gas Ltr/min ₹/Ltr per Annum ₹/Annum
Sr.No
(A) (B) (A) X (B)
1 Natural Gas 9.0 2250 ₹ 20,250.00
2 Steam 10.5 1250 ₹ 13,125.00
Potential Savings per Annum
₹ 33,375.00
(Post rectification of identified leaks)

Page 3 of 4
(3) Summary of Report: -

The Leak detection audit brought forward a new avenue for energy saving by rectifying the identified
leaks. This will also prolong the life of Compressors by reducing their running hours, andthus MTBF
and overall maintenance.

It is highly recommended that such audit be conducted on at least half-yearly basis to bring about a
positive change in maintenance and production activities thus raising overall reliability, reducing
maintenance cost and enhancing profitability of the firm.

------ End of Report ------

Page 4 of 4
 Report | 7 Jul 2023

GRP PANOLI

created by:
Ajay Rajendra Yelve
SONAPHONE Serial:
10488
Leak Expert:
V1.6.3
number of measurements:
2
first - last measurement:
6 Jul 2023 - 6 Jul 2023

address: comment:
Mahadyuta Technical Solutions
Navi Mumbai, Cont: 9961854160
 SUMMARY
7 Jul 2023
GRP PANOLI
2|5

First measurement 6 Jul 2023 11:06:00

Last measurement 6 Jul 2023 11:24:46
Number of leafiages 2 (0 rated)
To be repaired? 2
Repaired 0
Total loss 0.00 l/min 0.00 m³/h
Repaired 0.00 l/min 0.00 m³/h
Not yet repaired 0.00 l/min 0.00 m³/h

Distribution of Leakages [Class] Distribution of total loss [%]

Class 1: ≤ 1 l/min

Class 2: ≤ 2.5 l/min

Class 3: ≤ 5.8 l/min

Class 4: ≤ 10 l/min

Class 5: > 10 l/min

Not rated
Repaired
 SUMMARY
7 Jul 2023

GRP PANOLI
3|5

Total Leak Cost Total cost of Leak

Sr.No Gas Ltr/min ₹/Ltr per Annum ₹/Annum
(A) (B) (A) X (B)

Natural
1 9.0 2250 ₹ 20,250.00
Gas

2 Steam 10.5 1250 ₹ 13,125.00

Potential Savings per Annum

₹ 33,375.00
(Post rectification of identified leaks)

Savings potential [%]

Potential savings
Savings

The process of estimating the amount of leakage in a compressed air system is part of DIN EN
ISO 11011. This process provides data for energy management systems in accordance with DIN
EN ISO 50001. In this report, the total loss is indicated in l/min and can be used to estimate the
financial losses associated with the leakage, if data on the energy costs incurred when
generating 1m³ of compressed air is available.

Disclaimer: SONOTEC has developed a process for classifying and estimating the total leakage losses of a system to the best of its knowledge and ability, based on flow
acoustics methods. SONOTEC shall in no way be held liable for the results generated through the application of this process, nor for any decisions made on the basis of such
results. All actions taken by the end user based on the results are the sole responsibility of the end user, who accepts full liability for any such actions.
 7 Jul 2023
GRP PANOLI
4|5
OVERVIEW

Loss Leq p Position Repair

No. Rating ID Gas Priority Tester Date Repair state technician Repair date
[l/min] [dB] [bar g] (Building/Area/System/Component)

1 10488-070 9.00 50 6.0 NG High Ajay 6 Jul 2023 …/…/…/… To be repaired 6 Jul 2023

2 10488-071 10.5 61 6.0 Steam High Ajay 6 Jul 2023 …/…/…/… To be repaired
 7 Jul 2023
GRP PANOLI
5|5
DETAILS

Loss Leq p
Rating ID Gas Priority Tester Date
[l/min] [dB] [bar g]

10488-070 0.00 50 6.0 NG High Ajay 6 Jul 2023

System: NG line
Location: NG line near Boiler
Gas: Natural Gas
Remark: NG leakage detected
near gauge

Position (Building/Area/System/Component) Repair state Repair technician Repair date

…/…/…/… To be repaired 6 Jul 2023

Loss Leq p
Rating ID Gas Priority Tester Date
[l/min] [dB] [bar g]

10488-071 0.00 61 6.0 NG High Ajay 6 Jul 2023

System: Autoclave 1
Location: Steam inlet line
Gas: Steam
Remark: Steam Leak detected
through Valve gland, with high
steam flow

Position (Building/Area/System/Component) Repair state Repair technician Repair date

…/…/…/… To be repaired