CASE17 · Manufacturing · Turbo compressed air
Using field measurements to optimize textile-factory compressed air
A one-week field campaign compares system power, airflow, pressure and required units. The proposal uses UPI and supply-demand balance to define operating scenarios for a large turbo-compressor system.
01 · CASE ANALYSIS
Operating challenge
Compressed-air energy depends simultaneously on production demand, unit efficiency, running units, pressure and control. The proposal therefore evaluates the complete utility system rather than judging compressors only in isolation.
Four units ran continuously during the field campaign, while average demand-based requirement was approximately 3.2 units. Pressure loss and IGV/BOV control were also considered.
02 · CASE ANALYSIS
Field measurements and annualization
Measured mean power was approximately 3,503 kW, airflow 25,882 Nm³/h, pressure 6.78 kg/cm² and UPI 0.135 kWh/Nm³.
The representative-period accounting gives approximately 32.52 GWh/year and KRW 3.252 billion/year. Annualizing the one-week field campaign gives approximately 30.68 GWh/year and KRW 3.068 billion/year. They cover different reference periods and are not interchangeable baselines.
| Indicator | Mean |
|---|---|
| Power | 3,503 kW |
| Airflow | 25,882 Nm³/h |
| Supply pressure | 6.78 kg/cm² |
| UPI | 0.135 kWh/Nm³ |
| Actual / required units | 4.0 / approximately 3.2 |
03 · CASE ANALYSIS
Operating proposal
Use demand-based equipment combinations, review supply-pressure setpoints against production minimums and distribution losses, and reduce venting or inefficient control regions. Analyze piping, valves, filters and end-use losses alongside compressor performance.
Coordinate cooling-water pumps and cooling-tower fans with compressor staging. The proposed workflow is metering/data integration, analysis, scenario design, staged field application and ongoing operating guidance.
04 · CASE ANALYSIS
Potential and verification
The 7–10% and KRW 200–300 million/year are proposal-stage estimates based on field measurements and prior optimization experience. They are not confirmed savings at this textile plant.
Verify electricity and UPI at comparable airflow demand, accounting for staging, pressure, operating hours and production conditions.
| Reference | Annual electricity | Annual cost / opportunity |
|---|---|---|
| Representative-period accounting | 32.52 GWh | KRW 3.252 billion cost |
| Field-campaign annual equivalent | 30.68 GWh | KRW 3.068 billion cost |
| Proposed improvement | 7–10% estimated | KRW 200–300 million/year potential |
05 · CASE ANALYSIS
Engineering lesson
Document the sampling period before annualizing a short campaign. A one-week annual equivalent is useful for scale, but is not automatically representative of a full year.
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