Capacity Testing of Compressor
(FAD Test)
Step 1 Isolate the compressor along with its receiver from rest of the system (close outlet valve of air
receiver tank)
Step 2 Shut off the compressor drive motor
Step 3 Drain water completely and remove compressed air from air receiver tank and distribution line till
the isolation valve
Step 4 Close the water drain valve tightly and note down the initial pressure on air receiver tank or on
the control panel
Step 5 Re-start compresor motor
Step 6 Note down the pressure when the motor cuts off
Step 7 Note the time taken for motor to cut off (from initial pressure to final pressure)
Fill only green coloured cells (please ensure figures with correct units when filling the cells. Use conversion
tables provided below if needed)
Parameters Units Values Unit Converter
Theoretical compressor capacity, rated m3/min 0.7 From To
Air receiver volume m 3
0.22 100 PSI 6.80 kg/cm2
Additional volume (Pipeline etc.) (This will be zero, if the isolation valve
is immediately after air receiver tank) m3 0.001 100 bar 100.00 kg/cm2
Total volume, V m3 0.221 100 CFM 2.83 m3/min
Initial pressure, P1 kg/cm2g 0 100 m3/hr 1.67 m3/min
Final pressure, P2 kg/cm2g 12 100 hp 75 kW
Atmospheric pressure kg/cm 2
a 1.02 1 Lit 0.001 m3
Time taken to reach P1 to P2 min 4.04
Compressor output in terms of measured Free Air Delivery (FAD) m /min
3
0.64
Volumetric Efficiency of air compressor % 92%
Prepared by STENUM Asia Sustainable Development Society
[Link]
Rated Measured
FAD (m3/hr) 42 38 kw/m3/hr 0.01
kW 5.5 5.7 Annual operating hour -
SEC (kW/m3/hr) 0.13 0.15 Annual m3 #VALUE!
savings potential in kWh #VALUE!
savings potential in Rs. #VALUE!
fill only green cells
*Calculations are done considering that compressor is able to achieve atleast 90% of the rated
Leakage Test of Compressor
Step 1 Conduct test when no equipment is consuming compressed air (all the end user points are
closed or user equipment is switched off), but air receiver tank outlet is open
Step 2 Run the compressor to obtain desired level of pressure
Step 3 Note the subsequent ‘load’ and ‘unload’ time for 3 or 4 continuous cycles and obtain
average values for load and unload times each
Fill only green coloured cells (please ensure figures with correct units when filling the cells. Use
conversion tables provided below if needed)
Parameters Units Values Unit Converter
Time on load, T (average) Sec 170 From To
Time unload, t (average) Sec 248 100 PSI 6.80 kg/cm2
Compressor capacity (rated) m3/min 0.70 100 bar 100.00 kg/cm2
% 40.67% 100 CFM 2.83 m3/min
Leakage Loss
m3/min 0.28 100 m3/hr 1.67 m3/min
Rated power of compressor motor (from motor name plate) kW 5.5 7.5 hp 5.625 kW
Specific power consumption kW/m3/min 7.86 1000 Lit 1 m3
Annual operating hours hrs 7,200
Annual energy saving potential, simply by stopping leaks kWh/yr 14,125
Electricity unit cost (average - by considering DG set use also) Rs./kWh 7.3
Annual monetary saving potential, simply by stopping leaks Rs. 103,114
*Considering 5% losses remains in system
Prepared by STENUM Asia Sustainable Development Society
[Link]
Reducing compressed air discharge pressure
Step 1 Note down the initial pressure
Step 2 Reduce the set pressure at compressor to minimum usable value at the machines / end user
Note the subsequent ‘load’ and ‘unload’ time for 3 or 4 continuous cycles and obtain average
Step 3 values for load and unload times.
Fill only green coloured cells (please ensure figures with correct units when filling the cells. Use conversion
tables provided below if needed)
Compressor specifications Compressor pressure settings
Description Units Values Present Pressure Proposed Pressure
Parameter
Measured power of compressor motor (from motor name plate) kW 5.5 kg/cm2g PSIg kg/cm2g PSIg
Motor efficiency (from motor name plate) hm % 92% Cut off, Pressure 12.0 174 8.0 116
Time on load, T (average) Sec Cut in, Pressure 8.0 116 7.0 102
Time unload, t (average) Sec
% Loading time % #DIV/0! Unit Converter
Annual operating hours hrs 7,200 From To
Annual loading hours hrs #DIV/0! 100 PSI 6.80 kg/cm2
Electricity unit cost (average - by considering DG set use also) Rs./kWh 9 100 bar 100.00 kg/cm2
% 14.43% 100 CFM 2.83 m3/min
Power savings, simply by reducing pressure
kW 0.86 100 m3/hr 1.67 m3/min
Energy savings, simply by reducing pressure kWh/year #DIV/0! 100 hp 75 kW
Annual monetary saving potential, simply by reducing pressure Rs./year #DIV/0! 1000 Lit 1 m3
Prepared by STENUM Asia Sustainable Development Society
[Link]
Air Compressor Units Values
Vr m3 41.50
Vo m3 0
Pi kg/cm2 0
Pf kg/cm2 8
t sec 1110
Tr deg.C 35
Ta deg.C 32
L % 0
Q FAD m3/min 17.77
Motor input kW 140.2
Motor . Eff 92%
Comp input kW 128.98
Specific Power kW/m /min
3 7.26
