Measuring actual compressor output

There are many ways to produce compressed air inefficiently – incorrect pressure settings, wasted energy during unloaded running, choosing the wrong compressor, etc…

The technical condition and age of a compressor also have a considerable effect on compressed air production efficiency, as they significantly influence its actual delivery capacity.

One energy company has first-hand experience of this. We took measurements there using an insertion flow meter capable of measuring flow in pipes up to 300 mm in diameter.

We found that none of the three compressors delivered the nominal output specified by the manufacturer. In the worst case, we measured 150 l/s instead of the expected 265 l/s, a 45% loss of output with electricity consumption remaining unchanged. This imbalance between output and consumption means an annual loss of CZK 1,400,000 for three compressors with an input power of 37 kW each.

In this case, we recommended immediate replacement with a new compressor, with a payback period of less than two years.