Compressed Air Energy Scorecard

Fast, transparent scoring based on specific power, pressure management, leakage, and control strategy with explainable benchmarks.

System Inputs

Average Power (kW) *

Average compressor package power during normal operation.

Average Flow *

Average delivered flow (prefer measured data).

Flow Unit

Header Pressure *

Average plant header pressure.

Header Unit

Required Pressure *

Minimum pressure at most critical end-use.

Required Unit

Leakage (%)

Leak rate as % of average demand. Leave blank if using off-shift flow.

Off-Shift Flow (optional)

Alternative to leakage %. We'll estimate leakage from this.

Off-Shift Unit

Header Fluctuation (±)

Optional: typical pressure variation around setpoint.

Fluctuation Unit

Hours / Year *

Total operating hours per year.

Tariff (₹/kWh) *

Electricity cost for savings estimates.

Control System

Select the best match for your control approach.

Performance Scores

Overall Score

Good performance; improvements likely in one or two areas.

Energy Performance Score

EPS is weighted: Efficiency 40% • Pressure 20% • Leakage 25% • Controls 15%.

Confidence

High

Average kW provided • Average flow provided • Required pressure provided • Leakage % provided

Specific Power: 18.00 kW/100 CFM (Good)

Excellent Good Average Poor Bands: ≤15.83 / ≤17.87 / ≤19.92 / >19.92 kW/100 CFM

Your position is ~32% (lower is better). You're in the Good range.

Component Scores & Analysis

Efficiency (Specific Power)

82 (Good)

Based on Specific Power = 18.00 kW/100 CFM at ~108.78 psig. Benchmarks (pressure-adjusted): Excellent ≤15.83, Good ≤17.87, Average ≤19.92, Poor >19.92. Current band: Good.

Pressure Optimization

87 (Excellent)

Pressure score considers excess header pressure and stability. Header: 108.78 psig, Required: 97.16 psig → Excess: 11.62 psig. Fluctuation (±): not provided (neutral default applied).

Leakage Management

55 (Average)

Leak score is based on leak % severity. Current leakage is 20.00% (provided directly as leakage %). Typical targets: ≤10% good, ≤5% best practice.

Control System

70 (Good)

Single VSD helps, but performance depends on correct trim/base setup and avoiding multiple machines unloading together. Control score is assigned from the selected control strategy (not from measurements). Current: 70.

Top Loss Drivers

Leakage is high (~20.00%).
Excess pressure is moderate (~11.62 psig).
Specific power (18.00 kW/100 CFM) is within 'Average' or better band.
Control strategy is reasonable (score 70).

Drivers are ranked by severity based on your inputs. For higher accuracy, log kW, flow and pressure for 7–14 days.

Potential Annual Savings

Leak Reduction (to 5%):

₹1,08,86,400 – ₹1,63,29,600

Pressure Optimization:

₹35,34,720 – ₹52,96,080

These are indicative ranges (±20%) based on the inputs provided. Confirm with 7–14 days of logging for higher accuracy.

Recommended Actions

Fast wins (0–4 weeks)

Conduct an ultrasonic leak survey and fix the largest leaks first; tag leaks and verify repair.
Isolate off-shift zones (valves) and stop non-production blow-offs where possible.
Reduce header setpoint in 1–2 psi steps and validate critical end-use pressure at the farthest point.
Continue monitoring specific power periodically to maintain efficiency.

Projects (1–6 months)

Implement a quarterly leak KPI (target ≤10%, stretch ≤5%) with a documented repair workflow.
Reduce pressure drops by addressing filters, separators, dryers, and undersized piping (measure ΔP).

How the scores are calculated (transparent method)

Energy Performance Score (EPS) is computed from four components:

Efficiency (40%): Specific Power = kW per 100 CFM, benchmarked against pressure-adjusted bands.
Pressure (20%): Excess pressure (header vs required) plus stability (optional fluctuation input).
Leakage (25%): Leak % severity using standard target bands (≤10% good, ≤5% best practice).
Controls (15%): Practical scoring from the selected control strategy (sequencing, VSD trim/base, etc.).

Overall Score defaults to EPS in this web version (fast and energy-focused). For comprehensive assessments, add maturity modules (metering, maintenance, governance) to blend scores (e.g., 75% EPS + 25% Maturity).

Assumptions used (important)

Pressure-energy relationship: Savings estimate assumes ~0.5% energy per 1 psi of excess pressure (conservative, indicative).
Specific power benchmarks: Base bands are referenced at ~100 psig and adjusted by +0.2% per psi difference to reflect pressure impact.
Savings ranges: Displayed as ±20% to remain realistic without full logging study.
Leakage estimation: If leakage % is not provided, it is estimated from off-shift flow relative to average flow (clamped to 0–60%).
Controls score: Derived from selected control type (qualitative), not from measured cycling/unload/bypass data.