REPORT ON

Compressed Air, Natural Gas & Steam

Leak Audit
USING

ULTRASOUND TECHNOLOGY
(Report No. MTSPL/12/2023-24 dated 14 July 2023)

Client details:-

GRP Pvt. Ltd.,

GIDC Ankleshwar, Ankleshwar, Gujrat
 LIST OF CONTENTS

(1) Introduction (Page-2)

(2) Executive Summary (Page-3)
(3) Summary of Report (Page-4)
(4) Appendix – Detailed Leak Report

Page 1 of 4
(1) Introduction: - An Ultrasound Technology based Compressed Air, Natural Gas & Steam
leak Audit was undertaken on 5th 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. Divyang Patel, Mrs. Shruti Patel
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,

• Natural gas Incomer, Transmission lines between Natural gas Incomer and Production
Area, all external distribution system of Natural gas Incomer

• Steam boilers, Steam distribution line, Production Area

• High Voltage Electrical Assets

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

(A) 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.

(B) Technology Used: - Air- Borne Ultrasound Technology

(C) Equipment Used: - Sonaphone – III (Make: SONOTEC, Germany)

Page 2 of 4
(2) Executive Summary: -

(A) Jobs Undertaken: Leak detection using Ultrasound Technology for Energy Saving by finding
leaks in Compressed Air Systems, Natural Gas Lines, Steam line. These leaks, 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 14 leakages were found in compressed air system accounting
for about 77.13 Ltrs/Min loss of air. Steam system accounted for about 128.16 Ltr/min. Expected
monitory savings post rectification of these leaks is about ₹1,79,482 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 77.13 250 ₹ 19,282.5

2 Steam 128.16 1250 ₹ 1,60,200
Potential Savings per Annum
₹ 1,79,482.5
(Post rectification of identified leaks)

(C) Electrical Inspection: Integrated Electrical Asset Condition Assessment exercise was
undertaken using both Air-Borne and Structure-Borne Ultrasound Technology to assess Voltage
related defects like Partial Discharge (PD), Corona, Tracking and Arcing at an early stage,
especially applicable for High Voltage System (>1000V) to avoid catastrophic failures like Arc flash
and Arc blasts.

Following two positions were identified to be having Partial Discharge related defects: -

(i) R-Phase HT connection on H-Pole (ii) HT Breaker at Plant side

Page 3 of 4
(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 4 of 4
 Report | 7 Jul 2023

GRP ANKLESHWAR

created by:
Ajay Rajendra Yelve
SONAPHONE Serial:
10488
Leak Expert:
V1.6.3
number of measurements:
14
first - last measurement:
5 Jul 2023 - 5 Jul 2023

address: comment:
Mahadyuta Technical Solutions
Navi Mumbai, Cont: 9961854160
 SUMMARY
7 Jul 2023
GRP ANKLESHWAR
2|11

First measurement 5 Jul 2023 11:26:29

Last measurement 5 Jul 2023 16:58:02
Number of leakages 14 (7 rated)
To be repaired? 9
Repaired 0
Total loss 77.13 l/min 4.63 m³/h
Repaired 0.00 l/min 0.00 m³/h
Not yet repaired 77.13 l/min 4.63 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
GRP ANKLESHWAR
3|11
 SUMMARY
7 Jul 2023

Total Leak Cost Total cost of Leak

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

1 Air 77.13 250 ₹ 19,282.5

2 Steam 128.16 1250 ₹ 1,60,200

Potential Savings per Annum

₹ 1,79,482.5
(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
7 Jul 2023
GRP ANKLESHWAR
4|11

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 10488-055 14.05 70 9.9 Air High Ajay 5 Jul 2023 …PRESSOR/…/Compressor tank Inlet To be repaired

2 10488-057 9.45 38 9.9 Air High Ajay 5 Jul 2023 …let pipe/…/coupling compressor side To be repaired

3 10488-058 9.31 37 9.9 Air High Ajay 5 Jul 2023 …Air tank inlet pipe/middle coupling/… To be repaired

4 10488-059 11.12 49 9.9 Air High Ajay 5 Jul 2023 … compressor line/middle coupling/… To be repaired

5 10488-060 10.53 45 9.9 Air High Ajay 5 Jul 2023 …compressor line/coupling and To be repaired
valve/…
6 10488-061 14.74 75 9.9 Air Low Ajay 5 Jul 2023 …compressor line/coupling and To be repaired
valve/…
7 10488-062 7.91 57 5.0 Air High Ajay 5 Jul 2023 …ey Viscometer/coupling and valve/… To be repaired
8 10488-063 0.00 34 5.0 NG Low Ajay 5 Jul 2023 …ey Viscometer/coupling and valve/… Not repaired

9 10488-064 0.00 51 23.0 STEAM High Ajay 5 Jul 2023 Autoclave/A2/1st floor/… To be repaired

10 10488-065 0.00 48 25.0 STEAM High Ajay 5 Jul 2023 Boiler 1/…/…/… To be repaired

11 10488-066 0.00 52 25.0 STEAM High Ajay 5 Jul 2023 Boiler 1/…/…/… To be repaired

12 10488-067 0.00 47 6.0 Unkno… Low Ajay 5 Jul 2023 Thermopac 2 delivery pipe/…/…/… To be repaired

13 10488-068 0.00 51 25.0 STEAM High Ajay 5 Jul 2023 B plant Autoclave 1/…/…/… To be repaired

14 10488-069 0.00 50 25.0 STEAM High Ajay 5 Jul 2023 B plant Autoclave 1/…/…/… To be repaired
 DETAILS
7 Jul 2023
GRP ANKLESHWAR
5|11

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

10488-055 14.05 70 9.9 Air High Ajay 5 Jul 2023

System: ETP Air Compressor

Location: Piston type
compressor
Gas: Air
Remarks: main tank Input line
Leakage detected

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

…/ETP AIR COMPRESSOR/…/Compressor tank Inlet To be repaired

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

10488-057 9.45 38 9.9 Air High Ajay 5 Jul 2023

System: Main Screw Compressor

Location: Out side of
compressor 1st coupling
Gas: Air
Remarks: Leakage observed at
compressorside coupling of Main
air tank inlet pipe

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

…ain Screw compressor/Main Air tank inlet pipe/…/coupling compressor side To be repaired
 DETAILS
7 Jul 2023
GRP ANKLESHWAR
6|11

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

10488-058 9.31 37 9.9 Air High Ajay 5 Jul 2023

System: Main Screw Compressor

Location: Inlet pipe of air tank
of compressor middle coupling
Gas: Air
Remarks: Leakage observed at
air tank of compressor middle
coupling

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

Main Screw compressor/Main Air tank inlet pipe/middle coupling/… Not repaired

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

10488-059 11.12 49 9.9 Air High Ajay 5 Jul 2023

System: K1
Location: Main compressor line
Gas: Air
Remarks: Leakage detected at
Valve waterdroplets also
observed

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

K1/Main compressor line/middle coupling/… To be repaired
 DETAILS
7 Jul 2023
GRP ANKLESHWAR
7|11

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

10488-060 10.53 45 9.9 Air High Ajay 5 Jul 2023

System: Fluting Machine

Location: Main compressor line
above the front wall
Gas: Air
Remarks: Leakage detected
near the coupling and valve

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

Fluting machine/Main compressor line/coupling and valve/… To be repaired

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

10488-061 14.74 75 9.9 Air Low Ajay 5 Jul 2023

System: Fluting machine

Location: Main compressor line
inside the room
Gas: Air
Remarks: Leak detected near
the coupling also the showing the
leakage effect on wall

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

Fluting machine/Main compressor line/coupling and valve/… Not repaired
 DETAILS
7 Jul 2023
GRP ANKLESHWAR
8|11

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

10488-062 7.91 57 5.0 Air High Ajay 5 Jul 2023

System: Lab, Mooney

Viscometer
Location: Right side of Mooney
viscometer -inlet pipe and valves
Gas: Air
Remarks: All coupling and Valve
areshowing leakage

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

Lab/Money Viscometer/coupling and valve/… To be repaired
 DETAILS
7 Jul 2023
GRP ANKLESHWAR
9|11

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

10488-064 0.00 51 23.0 STEAM High Ajay 5 Jul 2023

System: Autoclave A2
Location: Inlet pipe of steam
Gas: Stem
Remarks: 3leakges found on the
pipe line

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

Autoclave/A2/1st floor/… To be repaired

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

10488-065 0.00 48 25.0 STEAM High Ajay 5 Jul 2023

System: Boiler 2
Location: Valve near the Gauge
Gas: Air
Remarks: Leakage detected at
valve

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

Boiler 1/…/…/… To be repaired
 DETAILS
7 Jul 2023
GRP ANKLESHWAR
10|11

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

10488-066 0.00 52 25.0 STEAM High Ajay 5 Jul 2023

System: Boiler 1
Location: Safety valve at upper
side of boiler
Gas: Steam
Remarks: Poor condition of
safety valve

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

Boiler 1/…/…/… To be repaired

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

10488-067 0.00 47 6.0 Unknown Low Ajay 5 Jul 2023

System: Thermopac 2
Location: Thermopac Pipeline
overhead in Boiler room
Gas:
Remarks: Leakage of oil from
delivery line of Thermopac 2

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

Thermopac 2 delivery pipe/…/…/… Not repaired
 DETAILS
7 Jul 2023
GRP ANKLESHWAR
11|11

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

10488-068 0.00 51 25.0 STEAM High Ajay 5 Jul 2023

System: Plant B Autoclave 1

Location: Plant B Autoclave 1 at
1st floor
Gas: Steam
Remarks: Leakage detected at
outlet pipeof steam

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

B plant Autoclave 1/…/…/… To be repaired

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

10488-069 0.00 50 25.0 STEAM High Ajay 5 Jul 2023

System: Plant B Autoclave 2

Location: Plant B Autoclave 2 at
1st floor
Gas: Steam
Remarks: Leakage detected at
outlet pipeof steam:

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

B plant Autoclave 1/…/…/… Not repaired