Air Energy Audit Savings Estimator

1. Commercial / plant assumptions

Electricity rate (PKR/kWh)

CO₂ factor (kg CO₂/kWh)

Operating days/year

The electricity rate is fully editable. Replace the CO₂ factor with the factor used by the client's ESG/carbon-accounting methodology when available.

2. Compressor data

Compressor / room

Rated motor power (kW)

FAD (m³/min)

Running hours/day

On-load hours/day

Off-load hours/day

Cut-in pressure (bar)

Cut-out pressure (bar)

Demand pressure required (bar)

Control

Dryer

Standby strategy

Compressor	kW	FAD	Run h/day	On-load	Off-load	Pressure	Control	Action

3. Demand-side / system information

Storage tank capacity (m³)

Leakage estimate (% of average generation)

Potential pressure reduction (bar)

Control / sequencing improvement (%)

System efficiency improvement (%)

Air-use / process optimization (%)

These are opportunity assumptions, not guaranteed savings. For a formal Air Energy Audit proposal, replace them with measured audit results such as kW, flow, pressure profile, leakage test, compressor-control response and production demand.

4. Results

Estimated baseline electricity

kWh/year

Baseline electricity cost

PKR 0

/year

Estimated annual energy saving

kWh/year

Estimated annual cost saving

PKR 0

/year

Saving potential

of baseline electricity

CO₂ reduction

kg CO₂/year

CO₂ reduction

tonnes/year

Current pressure band

bar

Calculation rules & methodology

Calculation	Formula / rule	Purpose
Baseline loaded energy	Motor kW × on-load hours/day × operating days/year	Estimated compressor energy while loaded.
Baseline unloaded energy	Motor kW × off-load hours/day × unloaded-power factor × operating days/year	Fixed-speed unloaded energy penalty. Default unloaded factor = 25%.
Baseline total	Loaded + unloaded energy	Estimated annual compressor electricity.
Leakage opportunity	Baseline × leakage % × 0.70	Conservative energy-saving conversion; not all leakage can necessarily be eliminated.
Pressure reduction	Baseline × pressure-saving factor	Approx. 7% energy reduction per 1 bar reduction as a screening rule.
Sequencing/control	Baseline × control improvement %	Reduction from better compressor sequencing and less unnecessary unloading.
System efficiency	Baseline × efficiency improvement %	Efficiency measures such as optimization, maintenance and operating-point improvements.
Air-use/process	Baseline × process optimization %	Reduction in unnecessary air demand.
Total saving	Sum of opportunity savings, capped at 35% of baseline	Prevents the screening calculator from producing an unrealistic aggregate saving.
Cost saving	kWh saved × electricity tariff	Annual PKR saving.
CO₂ saving	kWh saved × CO₂ factor	Annual avoided Scope 2 emissions using the selected factor.

This is a screening model, not a replacement for a calibrated power/flow audit. Final savings should use measured electrical power, FAD/flow, pressure, operating profile and production data.

Recommended Air Energy Audit inputs

Electrical
True kW, kWh, current, voltage, PF, load/unload profile.

Air
FAD/flow, pressure, dew point and demand profile.

Control
Cut-in/cut-out, VFD/FSD, sequencing and standby logic.

Leakage
Leakage survey or off-shift demand test.

Network
Piping size/layout, pressure drops, storage and dryers.