REPORT ON

Compressed Air, Natural Gas & Steam

Leak Audit
USING

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

Client details:-

GRP Pvt. Ltd.,

MIDC Chincholi, Solapur, Maharashtra
 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 3
(A) Introduction: - An Ultrasound Technology based Compressed Air, Natural Gas & Steam
leak Audit was undertaken on 10th 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. Parmeshwar Birajdar, Mrs. Rahul Adaki
ICICI Lombard GIC Ltd. Chirag Jaju
Representative
Condition MonitoringInspectors Mr. Ajay Yelve

Focus areas during inspection were as follows

• 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,

• Steam boilers, Steam distribution line, Production Area

• HT yard, LT room

Objective: - The main objectives of this exercise was to detect all minor and major leaks in
Compressed Air, Steam System & Electrical HT & LT to find energy losses due to these 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)

Page 2 of 3
(2) Executive Summary: -
(A) Jobs Undertaken: Leak detection using Ultrasound Technology for Energy Saving by finding
leaks in Compressed Air Systems, Steam line & Partial Discharge detection in HT & LT system.
These defect, being very small in intensity but large in numbers,could not be traced normally in noisy
and activity laden shop floors.

(B) Results of Inspection: A total of 22 leakages were found in compressed air system accounting
for about 62.53 Ltrs/Min loss of air and about 272.07 Ltrs/Min in Steam system. Expected
monitory savings post rectification of these leaks is about ₹ 3,55,720 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 from lesser 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

Sr.No Gas Ltr/min ₹/Ltr per Annum ₹/Annum
(A) (B) (A) X (B)
1 Air 62.53 ₹ 250 ₹ 15,632.5
2 Steam 272.07 ₹ 1250 ₹ 3,40,087.5
Potential Savings per Annum
₹ 3,55,720.00
(Post rectification of identified leaks)

(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, and thus 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 3 of 3
 Report | 11 Jul 2023

GRP CHINCHOLI

created by:
Ajay R. Yelve
SONAPHONE Serial:
10488
Leak Expert:
V1.6.3
number of measurements:
22
first - last measurement:
10 Jul 2023 - 10 Jul 2023

address: comment:
Mahadyuta Technical Solutions
Navi Mumbai, Cont.: 9961854160
 SUMMARY
11 Jul 2023
GRP CHINCHOLI
2|15

First measurement 10 Jul 2023 12:28:25

Last measurement 10 Jul 2023 16:20:52
Number of leafiages 22 (6 rated)
To be repaired? 18
Repaired 0
Total loss 62.53 l/min 3.75 m³/h
Repaired 0.00 l/min 0.00 m³/h
Not yet repaired 62.53 l/min 3.75 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
11 Jul 2023

GRP CHINCHOLI
3|15

Total Leak Cost Total cost of Leak

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

1 Air 62.53 ₹ 250 ₹ 15,632.5

2 Steam 272.07 ₹ 1250 ₹ 3,40,087.5

Potential Savings per Annum

₹ 3,55,720.00
(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.
 OVERVIEW
11 Jul 2023
GRP CHINCHOLI
4|15

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 10488-076 12.08 78 7.0 Air High Ajay 10 Jul 2023 …/…/…/… To be repaired

2 10488-073 11.10 68 7.0 Air High Ajay 10 Jul 2023 …/…/…/… To be repaired

3 10488-074 10.39 62 7.0 Air High Ajay 10 Jul 2023 …/…/…/… To be repaired

4 10488-072 10.35 61 7.0 Air High Ajay 10 Jul 2023 …/…/…/… To be repaired

5 10488-075 9.82 57 7.0 Air High Ajay 10 Jul 2023 …/…/…/… To be repaired

6 10488-077 8.79 48 7.0 Air Low Ajay 10 Jul 2023 …/…/…/… Not repaired

7 10488-078 0.00 49 20.0 STEAM High Ajay 10 Jul 2023 …/…/…/… To be repaired

8 10488-079 0.00 79 17.0 STEAM High Ajay 10 Jul 2023 …/…/…/… To be repaired

9 10488-080 0.00 84 17.0 STEAM High Ajay 10 Jul 2023 …/…/…/… To be repaired

10 10488-081 0.00 68 17.0 STEAM Low Ajay 10 Jul 2023 …/…/…/… Not repaired

11 10488-082 0.00 52 17.0 STEAM Low Ajay 10 Jul 2023 …/…/…/… Not repaired

12 10488-083 0.00 58 17.0 STEAM High Ajay 10 Jul 2023 …/…/…/… To be repaired

13 10488-084 0.00 68 17.0 STEAM High Ajay 10 Jul 2023 …/…/…/… To be repaired

14 10488-085 0.00 69 17.0 STEAM High Ajay 10 Jul 2023 …/…/…/… To be repaired

15 10488-086 0.00 71 17.0 STEAM High Ajay 10 Jul 2023 …/…/…/… To be repaired

16 10488-087 0.00 90 17.0 STEAM High Ajay 10 Jul 2023 …/…/…/… To be repaired

17 10488-088 0.00 52 17.0 Unkno… High Ajay 10 Jul 2023 …/…/…/… Not repaired

18 10488-089 0.00 40 17.0 Unkno… High Ajay 10 Jul 2023 …/…/…/… To be repaired

19 10488-090 0.00 54 17.0 Unkno… High Ajay 10 Jul 2023 …/…/…/… To be repaired

20 10488-091 0.00 50 17.0 Unkno… High Ajay 10 Jul 2023 …/…/…/… To be repaired

21 10488-092 0.00 35 17.0 Unkno… High Ajay 10 Jul 2023 …/…/…/… To be repaired

22 10488-093 0.00 36 17.0 Unkno… High Ajay 10 Jul 2023 …/…/…/… To be repaired
 DETAILS
11 Jul 2023
GRP CHINCHOLI
5|15

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

10488-076 12.08 78 7.0 Air High Ajay 10 Jul 2023

System: Thermic Fluid steam

generator
Location: Pneumatic vale
Gas: Air
Remark: Air leakage detected

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

…/…/…/… To be repaired

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

10488-073 11.10 68 7.0 Air High Ajay 10 Jul 2023

System: WTR Packing

compressor
Location: Out let pipe of air tank
near air tank
Gas: Air
Remark: Leakage detected near
valve

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

…/…/…/… To be repaired
 DETAILS
11 Jul 2023
GRP CHINCHOLI
6|15

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

10488-074 10.39 62 7.0 Air High Ajay 10 Jul 2023

System: Boiler room compressor

Location: Outlet pipe red pipe
Gas: Air
Remark: Air Leakage detected
at inlet of red pipe

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

…/…/…/… To be repaired

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

10488-072 10.35 61 7.0 Air High Ajay 10 Jul 2023

System: Lab Air compressor

Location: Outlet pipe near
gauge of Air tank
Gas: Air
Remark: Air Leakage detected

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

…/…/…/… To be repaired
 DETAILS
11 Jul 2023
GRP CHINCHOLI
7|15

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

10488-075 9.82 57 7.0 Air High Ajay 10 Jul 2023

System: Boiler room compressor

Location: Outlet pipe green color
Gas: Air
Remark: Leakage detected at
inlet of green pipe

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

…/…/…/… To be repaired

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

10488-077 8.79 48 7.0 Air Low Ajay 10 Jul 2023

System: Boiler room Output line

Location: Boiler output line
Autoclave 3
Gas: Steam
Remark: Steam and water
Leakage detected near the valve.

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

…/…/…/… Not repaired
 DETAILS
11 Jul 2023
GRP CHINCHOLI
8|15

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

10488-079 0.00 79 17.0 STEAM High Ajay 10 Jul 2023

System: BT plant
Location: BT plant steam main
line input
Gas: Steam
Remark: Steam leak detected at
flange near valve.

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

…/…/…/… To be repaired
 DETAILS
11 Jul 2023
GRP CHINCHOLI
9|15

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

10488-080 0.00 84 17.0 STEAM High Ajay 10 Jul 2023

System: BT Plant input line

Location: Input line of
Autoclave 7
Gas: Steam
Remark: Steam leakage
detected at flange near valve

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

…/…/…/… To be repaired

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

10488-081 0.00 68 17.0 STEAM Low Ajay 10 Jul 2023

System: BT Plant input line

Location: Input line of
Autoclave 4
Gas: Steam
Remark: Steam leakage
detected at flange near valve

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

…/…/…/… Not repaired
 DETAILS
11 Jul 2023
GRP CHINCHOLI
10|15

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

10488-082 0.00 52 17.0 STEAM Low Ajay 10 Jul 2023

System: BT Plant Autoclave 4

Location: Steam Output Line of
Autoclave 4
Gas: Steam
Remark: Leakage detected on
valve between two flanges.

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

…/…/…/… Not repaired

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

10488-083 0.00 58 17.0 STEAM High Ajay 10 Jul 2023

System: BT plant autoclave 5

Location: Discharge line of
Steam Autoclave 5
Gas: Steam
Remark: Leakage detected at
valve between two flanges in
discharge line.

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

…/…/…/… To be repaired
 DETAILS
11 Jul 2023
GRP CHINCHOLI
11|15

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

10488-084 0.00 68 17.0 STEAM High Ajay 10 Jul 2023

System: BT Plant Autoclave 5

Location: Autoclave 5 Safety
Valve
Gas: Steam
Remark: Leakage of steam
Detected.

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

…/…/…/… To be repaired

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

10488-085 0.00 69 17.0 STEAM High Ajay 10 Jul 2023

System: BT plant Discharge line

Location: Discharge line near
autoclave 4
Gas: Steam
Remark: Heavy leakage of
steam & hot water detected

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

…/…/…/… To be repaired
 DETAILS
11 Jul 2023
GRP CHINCHOLI
12|15

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

10488-086 0.00 71 17.0 STEAM High Ajay 10 Jul 2023

System: BT plant autoclave 6

Location: Autoclave 6 safety
valve
Gas: Steam
Remark: steam Leakage
detected at safety valve of
autoclave 6

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

…/…/…/… To be repaired

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

10488-087 0.00 90 17.0 STEAM High Ajay 10 Jul 2023

System: BT plant Autoclave 9

Location: Discharge line of
steam
Gas: Steam
Remark: Steam leakage
detected at coupling
between two flanges.

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

…/…/…/… To be repaired
 DETAILS
11 Jul 2023
GRP CHINCHOLI
13|15

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

10488-088 0.00 52 17.0 Unknown High Ajay 10 Jul 2023

System: BT plant Thermopac 10

line
Location: Thermopac 10 over
head line between autoclave 6&9
Gas: Oil
Remark: Leakage of oil detected
at flange

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

…/…/…/… Not repaired

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

10488-089 0.00 40 17.0 Unknown High Ajay 10 Jul 2023

System: BT plant Thermopac 10

line
Location: Thermopac 10 over
head line between autoclave 6&9
Fluid: Oil
Remark: Leakage of oil detected
at flange.

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

…/…/…/… To be repaired
 DETAILS
11 Jul 2023
GRP CHINCHOLI
14|15

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

10488-090 0.00 54 17.0 Unknown High Ajay 10 Jul 2023

System: BT plant Booster

pump 6
Location: Booster pump 6 pump
discharge end
Fluid: Oil
Remark: Oil leakage detected at
discharge of pump.

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

…/…/…/… To be repaired

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

10488-091 0.00 50 17.0 Unknown High Ajay 10 Jul 2023

System: BT plant Booster

pump 7
Location: Booster pump 7 pump
discharge end
Fluid: Oil
Remark: Oil leakage detected at
discharge of pump.

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

…/…/…/… To be repaired
 DETAILS
11 Jul 2023
GRP CHINCHOLI
15|15

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

10488-092 0.00 35 17.0 Unknown High Ajay 10 Jul 2023

System: BT plant Booster

pump 4
Location: Booster pump 4 pump
discharge line
Fluid: Oil
Remark: Oil leakage detected at
discharge line valve.

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

…/…/…/… To be repaired

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

10488-093 0.00 36 17.0 Unknown High Ajay 10 Jul 2023

System: BT plant Booster

pump 8
Location: Booster pump 8 pump
discharge line
Fluid: Oil
Remark: Oil leakage detected at
discharge line valve.

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

…/…/…/… To be repaired