© 2008 Data Power Services, LLC By: Tom Taranto 2010 Energy Expo Hosted by National Grid NYSERDA Reducing Compressed Air Energy Cost Using a Systems Approach

© 2008 Data Power Services, LLC By: Tom Taranto

2010 Energy ExpoHosted by

National GridNYSERDA

Reducing Compressed Air

Energy Cost

Using a Systems Approach

Tom Taranto


Systems Approach plant efficiency: energy >> product

Supply

CompressorsFilters / Dryers

PipingPrimary Storage

Transmission

PipelinesFilters / Dryers

Secondary Storage

Demand

Machines / ProcessPoint of Use Piping

Filters / DryersStorage Tanks

Energy Product

Power House / Compressor Room

Manufacturing Plant /Production Floor

Producers of Compressed Air

Consumers of Compressed Air

Produce Compressed Air More Efficiently

Consume Less Compressed Air

TotalEnergy

Reduction

Eliminate Irrecoverable

Pressure Loss


Systems Approach cost of ownership

Equipment cost and maintenance cost represent only a small part of the total cost of operating a compressed air system.

Electrical cost usually exceeds 75% of the total operating expense.

Source: Compressed Air Challenge®


Systems Approach energy flow

Energy Input

100 kW

5% Motor and Drive Efficiency

80% Heat of Compression

5% to 10% Waste: Irrecoverable Pressure Loss Leakage Artificial Demand

Inappropriate Use

10% to 5% Productive use


Systems Approach demand side energy reduction

50 % Productive Demand

5% Excessive Pressure

10% Inappropriate Use

15% Artificial Demand

20% Leakage Loss


Reduce Air Demand

Improve Compressor

Control

Systems Approach

Reduce Air Demand

Reduce System Pressure

Improve Compressor Control


Reducing Compressed Air Energy CostUsing a Systems Approach

Compressed Air Efficiency Services


Assessment of the Market for Compressed Air Efficiency Services


Assessment of the Market for Compressed Air Efficiency Services

Office of Industrial Technologies (2001) Office of Energy Efficiency and Renewable

Energy - U.S. Dept. of Energy Oak Ridge National Labs Motor Market

Assessment by XENERGY (1998) Pacific Gas & Electric “Compressed Air Market

Transformation Program” (1999)


Key Findings

Awareness and concern for energy efficiency is low.

Principal objective is consistent reliable air supply.

Serious problems reported. 35% had shutdowns in past 12 months 21% were shutdown for 2 or more days


0%

5%

10%

15%

20%

25%

30%

35%

40%

45%

50%

Percent of PlantsReporting the Problem

Don'tKnow

NoProblem

LowSystem

Pressure

Low LocalPressure

Oil in theAir

PluggingFilters

Water inthe Air

Type of Problem

Reported Air SystemProblems


Summary

71% Consistent, Reliable Performance - primary objective.

Only 17% “mentioned” efficiency.

35% Have had serious problems this yr.

Apply the Systems Approach



Identify Opportunities


Reducing Compressed Air Operating CostIdentify Opportunities

Compressed air – primary functions Power

As an energy source to perform work

Process Air becomes part of a process

Control To stop, start or regulate the

operation of a machine


Identify Opportunities highest priority

Reliability of the Production Process Deliver Energy to Production

Stakeholder’s needs Reliable production – no production outages Maintain product quality – minimum scrap and rework

Little energy concern if production is affected


Identify Opportunities sustainable energy savings

Comprehensive solutions Improve critical production end use applications Eliminate irrecoverable pressure loss Provide compressed air energy storage Optimize compressor control

Solutions must be long term and reliable If production is interrupted the energy efficient solution will be

abandoned in favor of the previous more energy intensive operation.

Improving Performance Reducing Energy



Improve PerformanceFix LeaksReduce System Pressure


Improve Performancepoint of use pressure profile

Test Machine Flow Dynamic Demand What’s Wrong With This Picture?



Validate Perceived High Pressure Pressure Gauges – Mechanical Damping

Air System AuditPoint of Use (P5) Pressure @ Test Machine

74

79

84

89

94

99

104

11:05 11:10 11:15 11:20 11:25 11:30

Time of Day 11/13/92

Ave

rag

e P

ress

ure

(P

SIG

)

P3 Pressure P4 @ Test Area Average P5 Minimum P5



Air System AuditDamper Cylinder Performance

0

10

20

30

40

50

60

70

80

90

18:0

4:48

18:0

4:53

18:0

4:59

18:0

5:05

18:0

5:10

18:1

4:48

18:1

4:54

18:1

5:01

18:1

5:08

Pre

ssu

re (

PS

IG)

Rod End Cap End9/14/94



Diagnostic DataARPAC Wrapper



Diagnostic Data - ARPAC Wrapper


Improve Performanceeliminate artificial demand

15% Artificial Demand Applying Pressure (PSIG) to an Orifice will

Increase Flow Rate (SCFM)


Annual Cost of Compressed Air Leaks @ 100 PSIG

Hole Diameter

Leak Rate SCFM

Annual Air Waste MMcf

Cost @ $293 / MMcf

Cost @ $463 / MMcf

1/32" 0.99 0.48 MMcf $139 $220

1/16" 3.96 1.90 MMcf $557 $880

3/32" 8.91 4.28 MMcf $1,253 $1,981

1/8" 15.84 7.61 MMcf $2,228 $3,521

5/32" 24.76 11.88 MMcf $3,482 $5,502

3/16" 35.65 17.11 MMcf $5,014 $7,923

7/32" 48.52 23.29 MMcf $6,824 $10,784

1/4" 63.38 30.42 MMcf $8,913 $14,085

Coeff. = 0.61 @ 100 PSIG 8000 Hours / Year Operation

Annual Cost of Compressed Air Leaks @ 80 PSIG

Hole Diameter

Leak Rate SCFM

Annual Air Waste MMcf

Cost @ $293 / MMcf

Cost @ $463 / MMcf

1/32" 0.82 0.39 MMcf $115 $182

1/16" 3.27 1.57 MMcf $460 $727

3/32" 7.36 3.53 MMcf $1,035 $1,635

1/8" 13.08 6.28 MMcf $1,840 $2,907

5/32" 20.44 9.81 MMcf $2,875 $4,543

3/16" 29.43 14.13 MMcf $4,140 $6,541

7/32" 40.06 19.23 MMcf $5,634 $8,903

1/4" 52.33 25.12 MMcf $7,359 $11,629

Coeff. = 0.61 @ 80 PSIG 8000 Hours / Year Operation

Improve Performancereduce leakage 20% Leakage Loss

Establish Leak Repair Priority Leak Repair is Most Effective if Pressure is Controlled


Reduce Pressure optimize the pressure profile

Demand side target pressure – lowest optimum pressure to support manufacturing Eliminate artificial demand Reduce compressor power 1% per 2 psig

Identify perceived high pressure demand – they prevent system pressure from being reduced. Validate the need for high pressure Check for piping restrictions Determine the present operating pressure (at the point of use)


Reduce Pressure optimize the pressure profile

If the need for high pressure is valid – do not let a small percentage of air demand cause the entire system to operate at high pressure.

Consider other ways to serve the high pressure need

Consider air amplifiers or booster compressors

Consider a separate dedicated compressed air system



Inappropriate Use of

Compressed Air

19


Inappropriate Useof compressed air

Compressed Air is Expensive and Inefficient $250 to $500 per Million Cubic Feet (MMCF) 80% to 85% of energy is waste heat 1 hp air motor requires 7 to 8 Hp at compressor 8 hp / 100 cfm – low pressure blower 23 hp / 100 cfm – 100 psig compressor Alternate sources are frequently 1/3 the energy cost of

compressed air Review Applications and Consider Alternative

Energy Sources

19



Abandoned & Malfunctioning Equipment

20



Air Powered Vacuum – 25 hp

21



Compressed Air Powered Cabinet Coolers 3300 watts input > 500

watts Cooling

Refrigerated Cabinet Cooler 750 watts input > 500

watts CoolingCompressed Air Cabinet Cooler

Refrigerated Cabinet Cooler

22



Idle Machine w/ Blowing Tubes Wasting Air

23



Air Operated Reciprocating Pump

24



Chip Blowing w/ Compressed Air

25



Air Motors Driving Ink Pumps

26



Compressed Air Blowing Tube

AIRNOZZLE

27



Air Powered Vacuum Generator

VACUUMGENERATOR

VACUUMCUPS

28



KEY Points – Inappropriate Air Use Compressed air is expensive and due waste heat at the

compressor, an inefficient power source. Using high pressure 100 psig air (23 Hp/100 cfm) for low

pressure 8 psig requirements (8 Hp/100 cfm) is inefficient. Review applications to investigate a more direct conversion of

energy supply (electricity) to the application requirements. Abandoned and malfunctioning equipment should be

eliminated or repaired. Air powered vacuums should be replaced with electric models

if possible.

28



KEY Points – Inappropriate Air Use Air powered cabinet coolers use 70% to 80% more energy than

small refrigeration units. Idle equipment should have compressed air automatically shut

off whenever possible. Air operated piston pumps should be replaced with electric

pumps if possible. Chip blowing applications can often use low pressure blowers

and delivery devices.

29



Monitor & Maintain System Efficiency


Monitor & Maintain System Efficiencymanagement information

Cost of compressed air is derived from reliably measured performance data.

Energy performance and cost are reported to management.

Compressed air demand of production operations is documented through airflow measurement and recording.

The consistent, reliable, supply of compressed air is achieved. Performance measurement information shows corrective measures to optimize performance.

Unscheduled downtime is minimized or eliminated.

40



Compressed Air Flow Measurement

34



36

Operating Profile Statistics Daily Profile Annual Profile Air Demand Profile24 hrs / day 3.45 MMCF / Day 1,256 MMCF / Year 2,395 scfm Avg. Airflow

7 days / week 15,142 kWH / Day 5,511,790 kWH / Year 3,201 scfm Max. Hourly Avg.52 weeks / year $1,211.19 / Day $440,943 Annual Cost 780 scfm Min. Hourly Avg.

Power Cost $50.47 / Hour (average) $351.07 / MMCF 3,667 scfm Max. Peak$0.0800 / kWH 631 kWH (average) $184.11 per cfm / yr. 36 scfm Min. Valley

Hourof theDay

Average Airflow (scfm)

Running Capacity

(cfm)

TotalPower(kWh)

OperatingCost

($ / hr.)

CompressedAir Cost$ / MMCF

CompressedAir Cost

$ / scfm / yr

SpecificPower

(kW/100 cfm)

SpecificPower

(bHp/100 cfm)

AveragePressure

(psig)0:00 1,586 4470 566.9 $45.35 $477.00 $250.02 35.7 47.9 113.81:00 3,189 4470 740.0 $59.20 $309.00 $161.97 23.2 31.1 114.82:00 2,150 4470 631.8 $50.55 $392.00 $205.47 29.4 39.4 114.13:00 2,051 4470 627.4 $50.19 $408.00 $213.86 30.6 41.0 114.24:00 3,120 4470 739.9 $59.19 $316.00 $165.63 23.7 31.8 114.95:00 780 4470 441.2 $35.30 $754.00 $395.22 56.6 75.9 114.66:00 2,404 4470 655.2 $52.42 $363.00 $190.27 27.3 36.6 113.67:00 3,108 4470 755.3 $60.42 $324.00 $169.83 24.3 32.6 115.08:00 2,830 5460 717.8 $57.42 $338.00 $177.17 25.4 34.1 114.09:00 1,739 5460 571.5 $45.72 $438.00 $229.58 32.9 44.1 112.2

10:00 2,659 5460 741.8 $59.35 $372.00 $194.99 27.9 37.4 113.211:00 3,012 5460 771.3 $61.70 $341.00 $178.74 25.6 34.3 115.112:00 2,832 4360 639.2 $51.13 $301.00 $157.77 22.6 30.3 114.013:00 1,779 4360 510.7 $40.86 $383.00 $200.75 28.7 38.5 112.014:00 2,951 4360 641.0 $51.28 $290.00 $152.01 21.7 29.1 114.315:00 3,201 4360 673.4 $53.87 $280.00 $146.76 21.0 28.2 114.916:00 2,876 4360 670.7 $53.65 $311.00 $163.01 23.3 31.2 113.417:00 2,601 4360 642.6 $51.41 $329.00 $172.45 24.7 33.1 112.918:00 2,642 4360 642.7 $51.42 $324.00 $169.83 24.3 32.6 112.919:00 2,171 4360 590.5 $47.24 $363.00 $190.27 27.2 36.5 112.920:00 3,117 4360 694.2 $55.53 $297.00 $155.68 22.3 29.9 114.521:00 965 4360 441.2 $35.29 $610.00 $319.74 45.7 61.3 110.522:00 2,035 4360 541.8 $43.34 $355.00 $186.08 26.6 35.7 112.623:00 1,682 4360 494.3 $39.54 $392.00 $205.47 29.4 39.4 112.7

NOTE: Minimum Maximum

ConservAIR ® Technologies, LLP COMPRESSED AIR SYSTEM MANAGEMENT… IT'S ALL WE DO © 2005 All Rights Reserved

Plant Air System AuditCompressed Air System Operating Profile on Thursday 11/11/2004



Summary:

2010 Energy ExpoHosted by:

National Grid & NYSERDA


Reduce Compressed AirOperating Cost


Improve Performance – Consistent Reliable Air Supply

Fix Leaks and Eliminate Waste

Reduce System Pressure and Eliminate Artificial Demand

Eliminate Inappropriate Use


Reduce Compressed AirOperating Cost


Target Pressure – Lowest Optimum Pressure

Improve Generation Efficiency – with Efficient Trim Compressors

Operate Multiple Compressors – Efficient Control Automation

Monitor & Maintain System Efficiency – Management Reports









Documents

© 2008 Data Power Services, LLC By: Tom Taranto 2010 Energy Expo Hosted by National Grid NYSERDA Reducing Compressed Air Energy Cost Using a Systems Approach