What it is
When pressure is higher than needed, unregulated users such as open blowing, leaks and some tools consume more air. That extra consumption is artificial demand: it adds nothing to production.
Where it shows up
Typical sources:
- Unregulated tools and open-ended blowing
- Leaks that flow more at higher pressure
- Processes using air at higher pressure than required
- Poor pressure control that allows large swings
How to reduce it
Practical measures:
- Lower the system pressure to what the process needs
- Regulate users that do not need full pressure
- Replace open blowing with nozzles or other efficient devices
- Improve control and storage so pressure is stable
Verify
Check that the processes still work, and measure power and pressure before and after. The saving depends on the plant.
Starting data
To start, it helps to have:
- Compressor make, model, rated power and controls
- Operating pressure settings and the lowest pressure the processes need
- Operating hours and shift pattern
- Any existing power, flow or pressure records
Frequently asked questions
Is artificial demand the same as leakage?
No, but they interact. Leaks flow more at higher pressure, so lowering pressure also reduces leakage.
How do I find it?
Measure flow and pressure, look for unregulated users and open blowing, and test the effect of a pressure change.
Will lowering pressure harm production?
Not if every process still receives its required pressure. Test in steps.
Field guide
Artificial demand: air you use only because pressure is high
Every open leak, unregulated blow-off and uncontrolled user consumes more air when system pressure is higher. This extra consumption is called artificial demand. Lowering pressure to what users actually need reduces it, on top of the saving at the compressor itself.
Where it comes from
- Leaks, whose flow rises with pressure.
- Open blowing nozzles and cleaning guns without regulators.
- Equipment supplied at full system pressure when it needs less.
How to reduce it
- Find the pressure each user actually needs, at the point of use.
- Fix pressure drops in filters and pipework so generation pressure can come down.
- Fit regulators on users that need less than system pressure.
- Use efficient nozzles and timer or sensor control on blow-offs.
- Lower generation pressure in steps, watching the most sensitive users.
Do not lower pressure blindly: one critical user may set the minimum. If only one user needs high pressure, a local booster may be cheaper than running the whole system high.
What to send for a quotation
- Compressor make, model and rated power of each machine.
- Electricity tariff and annual running hours.
- Typical pressure at the compressor and at the furthest user.
- Any measurements you already have (power, flow, loaded hours).
Send it through find my part or the spare parts enquiry, or call +91 99590 60718 or +91 92468 88812.